OM Handbook

OPERATIONS & MAINTENANCE
HANDBOOK
for
LP-GAS BULK STORAGE FACILITIES
Operations & Maintenance Handbook
for
LP-Gas Bulk Storage Facilities
Notice and Disclaimer Concerning Liability ................................................................. i
Propane Education & Research Council Industry Feedback Form ........................... ii
Section 1: Introduction – Purpose, Scope and Use of Handbook ............................. 4
Background and Purpose ....................................................................................4
Scope of Handbook .............................................................................................5
Using This Handbook ..........................................................................................6
Accessibility and Review......................................................................................7
Section 2: General Facility Information ....................................................................... 8
Section 3: Emergency Procedures Plan ...................................................................... 9
Section 4: General Operations & Safety Requirements............................................ 11
Site Accessibility ................................................................................................ 11
Site Signage and Markings ................................................................................ 11
Control of Combustible Materials and Ignition Sources ...................................... 11
Combustible Materials ....................................................................................... 12
Facility Ignition Sources ..................................................................................... 14
Containers – General Requirements .................................................................. 14
Site Storage ....................................................................................................... 16
Labeling .............................................................................................................16
Container Filling ................................................................................................. 17
General Requirements for LP-Gas Transfer Operations .................................... 18
Section 5: Plant Operations Procedures ................................................................... 20
5.1 Bulk Plant Operating Procedures ................................................................. 22
5.1.1 Bulk Storage Containers ............................................................................ 22
5.1.2 Loading a Cargo Tank Motor Vehicle (CTMV) Using a Plant Pump .......... 23
5.1.3 Loading a Cargo Tank Motor Vehicle (CTMV) Using a Plant Compressor 26
5.1.4 Unloading a Cargo Tank Motor Vehicle ..................................................... 30
5.1.5 Unloading a LP-Gas Railcar Using the Plant Compressor......................... 34
5.1.6 Preparation and Transportation of DOT Cylinders ..................................... 44
5.1.7 Preparation and Transportation of ASME Containers ............................... 55
5.1.7.3 DOT Regulations Pertaining to Transporting ASME Containers ........... 59
5.1.8 Evacuation of Containers .......................................................................... 62
5.1.9 Purging of Containers ................................................................................. 76
5.1.10 Dispensing LP-Gas................................................................................... 81
5.2 Vapor Distribution Systems .......................................................................... 88
Section 6: General Maintenance and Inspection Requirements .............................. 90
Maintenance Manuals ........................................................................................ 90
Maintenance Procedures ................................................................................... 90
Maintenance Record Keeping ............................................................................ 90
Maintenance Personnel - Training ..................................................................... 91
Physical Protection of Equipment ...................................................................... 91
Container Condition ........................................................................................... 91
Corrosion Control............................................................................................... 92
Containers and Appurtenances.......................................................................... 93
Emergency Shutoff Valves ................................................................................. 94
Hose Inspection and Maintenance ..................................................................... 94
Chart 6.1 (Sample) Preventive Maintenance Records ....................................... 95
Chart 6.2 (Sample) Fixed Equipment Log Repairs, Replacements and
Unscheduled Maintenance ................................................................................ 96
Chart 6.3 (Sample) ESV & Back Check Valve Testing Log ................................ 97
Section 7: Maintenance & Inspection Checklist Procedure ..................................... 98
Section Purpose and Objectives ........................................................................ 98
Scope and Application of Section ...................................................................... 98
Content of Section ............................................................................................. 99
Maintenance and Inspection Procedural Checklist ........................................... 100
Appendix 7.1.................................................................................................... 117
Bulk Storage Containers .................................................................................. 117
Piping .............................................................................................................. 124
Liquid Pump..................................................................................................... 127
Bulkheads ........................................................................................................ 132
Tank Car Unloading Tower .............................................................................. 140
Scales.............................................................................................................. 144
Meters (For Retail Sales Only) ......................................................................... 146
Vaporizers ....................................................................................................... 148
Regulators ....................................................................................................... 148
Electrical Systems ........................................................................................... 149
Section 8: Maintenance of Fire Protection Equipment ........................................... 152
Section Purpose and Objectives ...................................................................... 152
References ...................................................................................................... 152
General Requirements ..................................................................................... 152
8.1 Portable Fire Extinguishers ........................................................................ 152
Chart 8.1 (Sample) Maintenance & Inspection Record Portable Fire
Extinguishers ................................................................................................... 155
8.2 Water-Base Fire Protection Systems ......................................................... 156
Chart 8.2 (Sample) Maintenance & Inspection Record Water-Base Fire
Protection Systems .......................................................................................... 157
Section 9: Manufacturers’ Equipment Information ................................................. 158
Appendix A: References ........................................................................................... 159
Notice and Disclaimer Concerning Liability
The Propane Education & Research Council (PERC) is a non-profit 501(c)6 trade
organization authorized by the Propane Education and Research Act of 1996 (PERA), Public
Law 104-284. PERC was created “to enhance consumer and employee safety and training,
to provide for research and development of clean and efficient propane utilization equipment,
and to inform and educate the public about safety and other issues associated with the use
of propane.”
PERC is governed by a twenty-one member Board of Directors appointed by the National

Propane Gas Association (NPGA) and the Gas Processors Association (GPA). PERC
program beneficiaries include propane retail marketers, producers, transporters’ and
agricultural cooperatives, as well as representatives of allied service and supply industries
(industry members).
The recommendations, standards, or recommended practices, as reflected in this document,

were developed by independent consultants retained by PERC. While PERC administers
the process of obtaining the information, it does not independently test or verify the accuracy
of the information or methods used to collect the data that supports the conclusions or
recommendations reflected in this document.
PERC, NPGA, GPA and the industry members disclaim any liability for any personal injury,
property damage, business losses or other damages of any nature whatsoever, whether
special, indirect, consequential or compensatory, directly or indirectly resulting from the
publication, use, or reliance on this document, or any information, apparatus, method,
process, or similar item disclosed in this document. This disclaimer of liability shall apply
even if such loss or damage results, in whole or in part, from any acts or omissions of or by
any negligence on the part of PERC, NPGA, GPA or industry members or any persons who
contributed to the development of the information contained in this document. PERC,
NPGA, GPA and industry members make no warranty or guaranty as to the accuracy or
completeness of any information published in this document.
The procedures and information in this document are intended to implement the standards
set forth in the documents referenced with capabilities of the personnel and equipment
available. It does not create new standards or criteria for compliance. The order of steps in
any procedure may or may not be of importance. This material is not sold nor is it a product
of any consulting or engineering activity.
Users of this document should consult the law of their individual jurisdictions for codes,
standards and legal requirements applicable to them. This document is not intended nor should
it be construed to (1) set forth policies or procedures which are the general custom or practice in
the propane industry; (2) to establish the legal standards of care owed by propane distributors to
their customers; or (3) to prevent the user from using different methods to implement applicable
codes, standards or legal requirements.
By disseminating or publishing this document, PERC is not undertaking to render any

professional or other service to or on behalf of any person or entity. PERC, NPGA, GPA and
the industry members are not undertaking to perform any duty owed by any person or entity
to any third party. Anyone reading or using this document should rely on his or her own
judgment or, as appropriate, should seek the advice of a competent professional in
determining the exercise of reasonable care in any and all circumstances.
i
Propane Education &
Research Council
Industry Feedback Form
Program
Operations & Maintenance Manual
Section Page
Action Requested
New Text Graphic
Revised Text Other
Action and Reason for Proposed Action

Include proposed updated text or graphic, and supporting information.
Subject
Note: The subject should clearly and accurately express the main idea of your
suggestion.
For Example: Updated Distance Requirements.
ii
Propane Education &
Research Council
Industry Feedback Form
Reference or similar piece

Note: Type in details that reference and support your suggestion.
For Example: A document or book information (title, pages number, publication date and
publisher), a website address, or a federal organization name and regulation number.
Method of submitting reference material

Fax to (202) 452-9054 Regular Mail to
PERC
1140 Connecticut Ave, NW
Suite 1075
Washington, DC 20036
E-mail to
Other
courtney.gendron@propane.com
Note: If you are unable to type or print your reference details that reference and support
your suggestion, please choose a method.
You may support your suggestion with additional documents and materials. Propane
Education & Research Council encourages you to fax mail or e-mail additional
supporting materials.
Contact Information:
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Address:
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Phone:
Email:
You will receive a response, once the Industry Feedback Form is received. If you
do not receive a response within an appropriate time, please contact PERC at
(202) 452-8975.
iii
Operations & Maintenance Handbook Section 1
for LP-Gas Storage Facilities Introduction – Purpose,
Scope and Use of Handbook
Section 1: Introduction – Purpose, Scope and Use of Handbook
Background and Purpose
New requirements related to the operations and maintenance of bulk plant and industrial
plant LP-Gas systems were introduced in the 2001 Edition of NFPA 58, Liquefied
Petroleum Gas Code (Code) and expanded in the 2004 Edition. Specifically, in Chapter
14 of the 2004 Edition, the requirements summarily included:
 Operating procedure manuals for all such facilities.

 Written procedures describing actions for operating personnel to take in the
event of a release of LP-Gas in the facility.
 Maintenance manuals for all equipment at these facilities.
 Maintenance programs, including record keeping, for plant fire protection
equipment.
These requirements also included a provision that equipment owners and operators
must make sure that the procedures are updated “… whenever a major change occurs
that affects the operation of a system and prior to its startup.”
Three important changes were subsequently made in Chapter 14 of the 2008 edition of
NFPA 58:
 Retroactivity - The requirements of Chapter 14 were made applicable to new

and existing installations. This Code edition requires that written operations and
maintenance procedures be developed and maintained for those existing
installations that do not have this documentation.
 Exemption for Small Installations - Written operations or maintenance

procedures are not required for installations comprised of non-manifolded
multiple containers (in vapor service only) where the individual water capacity of
each container is no greater than 1,200 gallons and the aggregate does not
exceed 6,000 gallons.
As indicated in NFPA 58 §14.1, each LP-Gas retailer is required to meet the

requirements of chapter 14 at all new and existing bulk plants. Refer to the definition of
“Bulk Plant” in Chapter 3 of NFPA 58 and to Annex A of the Code for further explanatory
material. In addition, customer facilities that meet the definition of “Industrial Plant” will
need to prepare these procedures and manuals.
Because these requirements have been placed on essentially all retailers, PERC has
provided funds to develop and maintain a “tool” that contains a standardized approach
4
and format for LP-Gas retailers and industrial customers to readily use in order to meet
these requirements.
This Operations and Maintenance Handbook for LP-Gas Bulk Storage Facilities is both a
template and foundation document that allows owners and operators of LP-Gas bulk
plants and industrial plants to easily establish and have available in a common location
the necessary site information, procedures, manuals and charts used by and for:
 Plant personnel (employees and contractors) as ready reference for support and
guidance in emergency situations, plant operations (including startup and
shutdown), and maintenance activities.
 Record keeping associated with the required inspection and maintenance
activities.
 The authority having jurisdiction to verify the continuing safety of the LP-Gas
facility.
In summary, this handbook is intended to provide owners and operators of these

facilities the guidance and basic information to meet the intent and the requirements of
Chapter 14 of NFPA 58.
LP-Gas terminal operations (i.e., refrigerated storage, marine, pipeline and rail) are
typically mandated to meet the requirements of the OSHA Process Safety Management
(PSM) regulation under 29 CFR 1910.119 since they do not qualify for a “retail
operations” exemption to the standard. This handbook does not address the details of
those OSHA regulatory requirements.
While this handbook is not intended to be a training manual, every effort has been made
to be consistent with the procedural, technical and instructional information provided in
the Certified Employee Training Program (CETP) materials. Additionally, this handbook
does not intend to introduce, by reference or suggested best practice, any new practices
that should be considered additions to the regulatory agenda.
Scope of Handbook
Following this first introductory section, the handbook is divided into eight other sections.
Section 2, “General Facility Information,” provides the template for itemizing critical
emergency contact information for use by facility personnel, and with emergency
responders and any authority having jurisdiction. The information in this section
should be completed by the owner or operator of the facility and updated when
relevant changes occur.
Section 3, “Emergency Procedures Plan,” gives owners and operators assistance

regarding actions, procedures and documentation required by the Code in dealing
with an unintentional release of LP-Gas in the facility.
5
Section 4, “General Operations & Safety Requirements,” provides guidance,

procedures and charts for achieving compliance related to the general bulk
plant/facility operating and safety requirements in NFPA 58- 2014.
Section 5, “Plant Operations Procedures,” gives owners, operators and plant

personnel a “menu” of detailed operating procedures for bulk plant facilities and large
volume vapor distribution systems, including startup, normal operations and
shutdown.
Section 6, “General Maintenance and Inspection Requirements,” offers the

information necessary to comply with the general requirements for maintaining the
mechanical integrity of the facility. Sample charts are provided to meet the record
keeping requirements.
Section 7, “Maintenance and Checklist Procedure,” provides a bulk storage facility

maintenance and inspection checklist detailing many maintenance and inspection
steps that must be conducted in typical bulk storage and large volume vapor
distribution systems. This checklist is generally organized by LP-Gas system
components. Additionally, an appendix is included in this section that provides
technical assistance for completing the checklist reviews.
Section 8, “Maintenance of Fire Protection Equipment,” gives guidance for complying

with requirements associated with maintaining fire protection equipment, and charts
for recording the necessary information related to maintenance and inspection
activities.
Section 9, “Manufacturers’ Equipment Information,” has been intentionally left blank

in the original copy of the handbook provided to you. It is intended to be a
“bookmark” location for retaining/filing manufacturer’s literature related to the detailed
maintenance, inspection and repair information (including instructions and
procedures) specific to your LP-Gas bulk plant or industrial/commercial system.
Additionally, Appendix A, “References,” has been provided which lists the documents
that are referenced throughout this handbook. These references provide further
detailed information or work procedure instructions, reference data or training
information in order to meet the intent and requirements of the Code.
Using This Handbook
The ultimate purpose of this handbook is to be a functional document for each LP-Gas
storage facility and serve (in a combined role) as your facility’s operations, maintenance
and emergency procedures manuals, consistent with the requirements of Chapter 14 of
NFPA 58-2014.
Not all the information and materials contained in this handbook apply to each facility.
Also, it is possible that special situations or operations not encountered in a typical LP-
6
Gas storage facility might arise at any given site. Every effort has been made to address
the numerous scenarios that can occur in a bulk plant or large storage facility. However,
unique situations might not be included in this handbook. Therefore, each section should
be thoroughly reviewed by the owners and operators to include all applicable data,
information and procedural steps. Materials that are not applicable to your particular
facility can be removed.
At the beginning of each handbook section, the purpose and objective(s) of that section
are provided so that the readers, whether owners/operators or field personnel, can
understand the intent of the section and the scope of the regulatory subject that is being
addressed. Each section then has specific instructions regarding how to use its content
in order to achieve compliance with that regulatory requirement.
By nature of the subject matter, the sections differ in their respective approaches in
addressing each specific regulatory topic. For example, Section 5 on Plant Operations
Procedures should be considered as a “template” for the operations conducted at your
facility. Additions or deletions to these procedures might be necessary in order to
accurately reflect local operations and conditions. Section 7 provides a checklist and
guidance information for performing and documenting maintenance and inspection
activities required by the Code. Again, not all subparts will necessarily be applicable; so
those portions of the checklist can be removed. Other items might need to be added
under special circumstances.
Again, it is important to read the information at the beginning of each section so that the
information contained can be used most efficiently and effectively, especially for use by
plant and field personnel.
Accessibility and Review
When the information and procedures are developed into your facility’s operating,
maintenance and emergency procedures manual(s), these procedures and manual(s)
must all be available at the facility to which they apply and accessible to all
employees and users, including any authority having jurisdiction. Per NFPA 58,
maintenance manuals for normally unattended facilities are allowed to be stored at a
location where they are accessible for maintenance personnel serving the unattended
location.
The procedures should be reviewed with all appropriate employees and users who are
expected to carry out the relevant job functions at the time when the procedures are
initially developed and again when changes to the procedures occur.
NFPA 58 requires that all operation and maintenance procedures must be updated
whenever a change occurs that effects the operations or maintenance, and prior to
startup.
7
Operations & Maintenance Handbook
for LP-Gas Storage Facilities Section 2
General Facility
Information
Section 2: General Facility Information

Type of Facility: LP-Gas Bulk Storage Plant
Company Name:
Facility Name (if different):
Street Address:
City, State, Zip Code:
Facility Telephone Number:
Company Headquarters (city, state):
Original Date of Manual:
Revision Number and Date:
MANAGEMENT CONTACT INFORMATION
Authorized (Responsible) Facility Representative (name):

Title (Position) of Representative:
Representative’s Emergency Contact Telephone Number(s):

LOCAL EMERGENCY RESPONDER CONTACT INFORMATION
Fire Department (name):

□ Telephone Number:
Emergency Medical Responders (name):
Hospital or Emergency Medical Facility (name):
Police Telephone Numbers
□ State:
□ Local:
LP-Gas Inspection Agency (name):
Coast Guard Telephone Number (if applicable):
8
for LP-Gas Storage Facilities Emergency Procedures
Plan
Section 3: Emergency Procedures Plan

ISSUE INFORMATION
Issue Date:
This safety data sheet and the information it contains is offered to you in good faith as accurate. This
Supplier does not manufacture this product but is a supplier of the product independently
manufactured by others. Much of the information contained in this data sheet was received from
sources outside our Company. To the best of our knowledge this information is accurate, but this
Supplier does not guarantee its accuracy or completeness. Health and safety precautions in this
safety data sheet may not be adequate for all individuals and/or situations. It is the user's obligation to
evaluate and use this product safely, comply with all applicable laws and regulations and to assume
the risks involved in the use of this product.
NO WARRANTY OR MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSES, OR

ANY OTHER WARRANTY IS EXPRESSED OR IS TO BE IMPLIED REGARDING THE ACCURACY
OF COMPLETENESS OF THIS INFORMATION, THE RESULTS TO BE OBTAINED FROM THE
USE OF THIS INFORMATION OR THE PRODUCT, THE SAFETY OF THIS PRODUCT, OR THE
HAZARDS RELATED TO ITS USE.
9
for LP-Gas Storage Facilities Emergency Procedures
Plan
Legend: Fire Extinguisher =

Appendix 3.2
*Example only. Each facility
Sample Site Plan* should develop its own site plan.
Local Street/Highway
North
Vehicle Gate
Pedestrian Gate
Evacuation
Assembly Remote
Fire
Point Shutdown
Hydrant
P
A
R
Office and Transports and Bobtails, Only, In This Area
Retail Store K
I
N
G Loading/Unloading Station
Electrical
Panel Internal
ESV Valve
S
T 30,000
Service and O
Cylinder Delivery GWC
Cylinder Loading R
Filling Dock Trucks Only In A
This Area G
E
Empty Cylinder Storage

Fire (Open Area)
Emergency Exit Gate
Monitor
10
for LP-Gas Storage Facilities General Operations & Safety
Requirements
Section 4: General Operations & Safety Requirements
Section Purpose and Objectives
According to NFPA 58-2014 §14.2 (Operating Requirements), operating procedures that

address all aspects of LP-Gas transfer must be prepared and maintained for each facility in a
common location or locations. Owners and managers of LP-Gas bulk or industrial plant
systems should update the operating procedures whenever a major change occurs, and prior to
the startup of a changed system.
This section provides guidance for achieving compliance with those referenced requirements
related to general bulk plant/facility operating procedures and safety requirements, exclusive of
emergency procedures that have already been addressed in Section 3 of this handbook.
Guidance specific to startup, operation and shutdown of the transfer system and equipment are
addressed in Section 5.
Site Accessibility
Except where business activities dictate, customers and the general public should be restricted
from areas where LP-Gas is stored, transferred and handled.
Site Signage and Markings
Signs and other forms of markings within the site or on the equipment should provide
appropriate warnings and sufficient information for personnel onsite to work safely and perform
duties consistent with procedures and work practices.
Control of Combustible Materials and Ignition Sources
Referring to Figure 4.1, basic fire prevention concepts demonstrate that the elimination of any
leg of the “fire triangle” will eliminate the possibility of combustion occurring.
Figure 4.1
11
Requirements
Therefore, the control of combustible materials and ignition sources is critical to the operating
safety of any LP-Gas facility, depending on specific site conditions.
Combustible Materials
Weeds, long dry grass, wooden materials (e.g., limbs, planks, pallets) and paper products are
all examples of combustible materials (i.e., “fuel”) that need to be controlled and kept at a
sufficient distance from LP-Gas storage containers in order to reduce the potential for a fire that
could occur adjacent to the equipment. All these and similar combustible materials must be
maintained or stored such that they are no closer than 10 feet to the container. Additionally,
where single containers (constructed as portable containers) are used for temporary storage,
they must not only be placed on level and firm surfaces but they also must be kept clear of
combustible materials (as defined in this paragraph) for a minimum distance of 10 feet.
Ignition Sources
Smoking
Another significant fire prevention measure is the control of ignition sources. First and foremost,
smoking prohibitions for each site must be established. As minimum requirements, no person,
whether that person is an employee, contractor or site visitor, can be allowed to use or carry
lighted smoking materials under the following situations:
 When he or she is on or within 25 feet of a vehicle that contains LP-Gas, liquid or vapor.
• When he or she is within 25 feet of a point of transfer while transfer operations are in
progress.
 When delivering to, or connecting to containers or disconnecting from containers.
Further smoking restrictions or prohibitions may be established by the owner or operator of the
site.
Open Flames & Other Ignition Sources – Continuous Control
Open flames and other ignition sources (such as non-explosion proof electrical equipment and
vehicles) must be controlled on an on-going basis for general fire prevention purposes. Specific
control measures that must be implemented include:
 Prohibiting open flames and all other sources of ignition in pump houses, cylinder filling
rooms and other locations where the presence of LP-Gas liquid or vapor is likely.
 Prohibiting the installation in pump houses or cylinder filling rooms of:

(a) Direct-fired vaporizers, or
(b) Indirect-fired vaporizers that are attached or installed
adjacent to gas-fired heat sources.
12
Requirements
 Prohibiting open flames, cutting or welding tools, sparking hand tools, portable electric
tools (including two-way radios and cell phones) and non-explosion proof electrical
equipment within the distances specified per Section 7.2.3.2 in NFPA 58.
 Installing all fixed electrical equipment and wiring within a classified area specified in
Table 6.23.2.2 in accordance with the requirements of NFPA 70, National Electric Code.
While open flames and other ignition sources are not prohibited in site locations where LP-Gas
equipment has been purged of all liquid and vapor, appropriate measures should be taken to
make sure that these locations remain gas-free.
Open Flames and Other Ignition Sources – Transfer Operations
Sources of ignition must be eliminated during all LP-Gas transfer operations, including the
periods when connections and disconnections are being made and while LP-Gas is being
vented to the atmosphere. During transfer operations the following specific precautions must be
taken:
 Internal combustion engines that are within 15 feet of the point of transfer must be shut down,
except for:
(a) Engines of LP-Gas cargo tank vehicles constructed and

operated in compliance with Chapter 9 of NFPA 58, when
these engines are being used to operate transfer pumps or
compressors on the vehicles themselves in order to load
containers that are not located at a stationary
installation (Note: This is not a typical bulk plant scenario.); or
(b) Engines in buildings as covered by Section 11.13 of

NFPA 58 (i.e., Industrial and Forklift Trucks Powered by LP-Gas).
 Smoking or the use of open flames, sparking hand tools, portable electric tools (including
two-way radios and cell phones), non-explosion proof electrical equipment or any other
equipment that has the energy to ignite LP-Gas must be prohibited within 25 feet of the
point of transfer.
 Metal cutting, grinding, oxygen-fuel gas cutting, brazing, welding, soldering or welding
(i.e., any “hot work” procedures) must be prohibited within 35 feet of the point of transfer.
Furthermore, if any of these procedures have been performed within this zone of 35 feet
prior to the transfer operation, the affected materials must be cooled to a temperature
below the ignition temperature of LP-Gas (i.e., approximately 900ºF) before starting the
transfer.
 For those facilities where LP-Gas is dispensed into a vehicle container for the purpose of
using the LP-Gas as a fuel source (e.g., a recreational vehicle or a propane-fueled
vehicle), all ignition sources associated with the vehicles must be turned off. Control
measures include (but are not limited to):
13
Requirements
(a) Shutting down the engines of the vehicle being fueled and those
waiting to be fueled; and
(b) Extinguishing pilot lights and shutting off other ignition sources
within recreational vehicles.
Facility Ignition Sources
Survey your facility and list the ignition sources in the data box, below. Insert an additional
sheet, if necessary.
Table 4.1 – Ignition Sources
TYPE/NATURE LOCATION CONTROLS OR

OF IGNITION SOURCE OF IGNITION SOURCE CORRECTIVE ACTION
Containers – General Requirements
ASME Containers (Pressure Vessels)
In general, stationary containers used for LP-Gas bulk plant storage must be designed,
fabricated, tested and marked in accordance with the requirements of the ASME Boiler
and Pressure Vessel Code, Section VIII or the API –ASME code if constructed prior to
July 1, 1961. The agency having jurisdictional authority (usually, that associated with
“boilers”) should be contacted for specific requirements related to compliance and
continued service use. The NFPA LP-Gas Code Handbook (2014 Edition) provides
additional background information, guidance and reference material.
ASME Container Data
For your record keeping, insert information from the data plates (nameplates) on the
ASME storage containers at your facility into Table 4.2. For additional ASME storage
containers, add another table and insert the appropriate information.
Table 4.2 – ASME Container Data
14
Requirements
CONTAINER #1 CONTAINER #2 CONTAINER #3 CONTAINER #4

Service (UG, AG)
Manufacturer’s
Name & Address
Manufacturer’s
Serial Number
Water Capacity
(lb or gal)
Maximum vapor pressure
of product permitted
MAWP (psi)
Outside Surface Area
(sq. ft.)
Year Built
Shell Thickness
(in.)
Head Thickness
(in.)
Overall Length
(ft.-in.)
Outside Diameter
(ft.-in.)
Head Design
Min. Design Metal Temp.
@ MAWP
ASME Code Symbol
Type Construction
Degree of Radiography
Liquid and Vapor Openings
The requirements for internal valves and other valve/line closure components for liquid
and vapor openings (both inlet and withdrawal) on ASME containers over 4,000 gallons
are defined in §5.7.4.2 of NFPA 58. Alternate provisions for installation of ASME
containers, including underground and mounded tanks of 2,001 gallon through 30,000
gallon water capacity are further provided in §6.28 of NFPA 58.
Portable Cylinders
These containers are designed, fabricated, tested and marked in accordance with the
U.S. Department of Transportation (DOT). This handbook is not intended to reiterate the
DOT requirements with respect to these aspects of the regulations. For details, refer to
Title 49, Code of Federal Regulations, “Transportation”. Again, the NFPA LP-Gas Code
Handbook (2014 Edition) provides additional background information, guidance and
reference material on these containers, also.
15
Requirements
Site Storage
A number of considerations must be taken into account when storing portable cylinders in a bulk
plant. These include:
 Locating them in a place that minimizes their exposure to excessive temperatures,

physical or mechanical damage and tampering.
 Positioning any cylinder that has a nominal LP-Gas capacity greater than 1 lb (0.45
kg) such that the pressure relief valve is in direct comunication with the vapor space
of the cylinder.
 When storing LP-Gas cylinders inside buildings (in accordance with §8.3 of NFPA
58, they cannot be located near any areas of egress (e.g., exits, entrances, and
walkways). Also, when determining the maximum quantity of LP-Gas that can be
stored indoors, each cylinder stored indoors must be considered to be a full cylinder.
 Cylinders cannot be stored on the roof of any building or structure.
Temporary Stationary Storage
In situations where a portable container is being used for temporary stationary storage in a bulk
plant, it must be placed on a firm flat surface (e.g., concrete pad, pavement or firm earth) while
in use as such.
Labeling
ASME Containers (> 2000 gallon water capacity)
The representative inlet and outlet connections for both the liquid and vapor spaces
must be labeled as such. While not required, color coding of the associated piping and
valves can be used as an identification aid in addition to labeling.
Connections for gauges and pressure relief devices are not required to be labeled.
Portable Cylinders
When LP-Gas cylinders are to be stored or used at the same sites with other
compressed gases, each cylinder must be labeled to identify its contents. The labeling
should be consistent with the requirements of ANSI/CGA C-7, Guide to the Preparation
of Precautionary Labeling and Marking of Compressed Gas Containers.
16
Requirements
Container Filling
Overfilling Prevention Devices (OPD)
NFPA 58 requires that cylinders with LP-Gas capacities of 4 lb through 40 lb be

equipped with an OPD and a fixed maximum liquid level gauge, and that no cylinder in
this capacity range can be filled if it is not equipped with both of these devices unless
specifically exempted from the requirement.
Those cylinders in the 4 lb - 40 lb capacity range that are exempt from having a listed
OPD installed include:
 Cylinders used in industrial truck service.

 Cylinders identified and used for industrial welding and cutting gases.
 Cylinders manufactured prior to October 1, 1998, and designed for use in the
horizontal position and where an overfilling prevention device is not available.
Liquid Level Gauges
Every container that is designed to be filled on a volumetric basis must be equipped with
a fixed maximum liquid level gauge in order to indicate the maximum fill level for the
service in which the container is to be filled or used.
For bulk plants or specific points of transfer that are designated as “low emission
transfer” locations (i.e., to meet environmental regulatory requirements or to take
advantage of reduced installation distances), fixed maximum liquid level gauges cannot
be used to determine the maximum filling limit. Therefore, the maximum permitted filling
limit must be determined by weight or other approved means.
Where variable liquid level gauges are also used for filling containers (usually large
capacity storage vessels), these devices must meet the following requirements to
facilitate reading the gauges:
 The gauges must show the maximum liquid level (in inches, metric units or
percent capacity of the container) when installed in containers greater than 1200
gallon water capacity; and
 Markings must indicate the maximum liquid level at liquid temperatures from 20ºF
to 115ºF and in increments not greater than 20ºF; and
 The system nameplate and/or the gauge must have markings indicating the
various liquid levels from empty to full; and
 Dials of rotary gauges or magnetic float gauges must indicate whether they are
for cylindrical containers or spheres, and if the service is aboveground or
underground; and
17
Requirements
 Dials of gauges for aboveground (only) containers that have a water capacity of
more than 1,200 gallons must be marked to note this fact.
General Requirements for LP-Gas Transfer Operations
Personnel
Individuals whose job duties are covered by NFPA 58 must be trained on proper
handling procedures specific to their duties. They must also receive training on
emergency response procedures.
Persons whose primary duties include transferring liquid LP-Gas or transporting LP-Gas
must receive training on the following:
• Safe work practices

• Health and safety hazards of LP-Gas
• Emergency response procedures
• Supervised on-the-job training
• An assessment of their ability to perform the job duties
Additionally, NFPA 58 requires that refresher training be provided every three (3) years,
and that the training be documented.
During the transfer operation, from the time of original connection through the final
disconnect, at least one qualified person must be in attendance. “In attendance” means
that the individual must have line of sight of the transfer operation and be in a position to
physically take action if required during the operation.
These persons are also responsible to make sure that the equipment and containers
used in the transfer operations are designed for the type of LP-Gas that is being filled
into the receiving container.
Furthermore, when these individuals observe non-compliant situations or conditions with

respect to containers and their appurtenances, the container owner and user must be
notified in writing.
Prohibitions
Compressed air, oxygen or any oxidizing gases cannot be injected into containers for
the purpose of transferring LP-Gas liquid. These gases can create a flammable gas
mixture within the container.
Similarly, when evacuating containers, no liquids or gases other than LP-Gas may be
injected into the containers.
18
Requirements
Containers used in Ammonia Service
Except for cargo tank service, ASME containers of 3,000 gallons water capacity or less
used to store anhydrous ammonia must not be converted to LP-gas fuel service.
LP-Gas stored or used in systems within the scope of this code shall contain less
ammonia than the quantity required to turn the color of red litmus paper to blue. The
initial fill of LP-Gas in a transportation or storage system that has been converted from
ammonia to LP-Gas service shall be tested for ammonia contamination prior to being
used or transferred from that system.
Brass fittings are commonly used in LP-Gas service. Ammonia will damage these brass
system components by a corrosion phenomenon commonly called “season cracking” (a
form of stress corrosion cracking), potentially resulting in unanticipated and premature
failure. It is important that LP-Gas is free of ammonia. Procedures on testing LP-Gas for
ammonia contamination are in Annex A of NFPA 58 (A.4.5).
19
for LP-Gas Storage Facilities Plant Operations
Procedures
Section 5: Plant Operations Procedures
NFPA 58-2014 requires that new and existing bulk and industrial plants prepare and maintain
written operating procedures in a common location. This section provides guideline operating
procedures for bulk plant facilities and industrial plants.
Scope and Application of Section
While operating procedures are typically similar at LP-Gas bulk storage facilities, the equipment
can vary in size (i.e., storage capacity), design, layout, equipment complexity or function (e.g.,
rail unloading facilities, cylinder filling operations, on-site commercial dispensers).
This handbook section should be considered to be a “template” for the operations conducted at
any specific LP-Gas bulk storage facility, and additions or deletions to these procedures could
be necessary. Therefore, owners or site management and supervisors should consider site-
specific features and conditions that need to be included, modified or deleted in the information
in this section in order to accurately reflect local operations and conditions. With these
changes, operators, technicians, drivers and other site personnel can use this document as the
operating procedures required by NFPA 58.
Operating procedures for large-volume storage and vapor distribution systems at customer
locations are also addressed in this section.
Although NFPA 58 references the need for documented operating requirements with respect to
refrigerated storage, marine and pipeline LP-Gas systems, these systems (which can vary
significantly in design and complexity) also come under the authority of jurisdictions which have
very specific and detailed requirements within EPA’s Risk Management Plan, OSHA’s Process
Safety Management and US DOT’s Office of Pipeline Safety. Therefore, these systems are not
addressed in this handbook.
Content of Section
The chart below is a guide for operators to easily identify which sections are appropriate for their
specific applications. Applicable CETP modules are included in the table for easy reference to
additional instructional information and materials.
The “CETP-2014 Reference” directs the user to the related module of the training materials
having a 2014 copyright date.
For CETP-2014, the references are constructed such that the first three letters designate the
course, followed by the applicable module and lesson (e.g., BPP-7-1).
 BPP - Basic Practices and Principles of Propane

 PDO - Propane Delivery Operations and Cylinder Delivery
20
Procedures
 BDO - Bobtail Delivery Operations

 BPO – Basic Plant Operations
 3.6 & 3.7 - Performing Railcar Product Transfers and Maintaining DOT Intermodal (IM)
Tanks
 4.1 - Designing and Installing Exterior Vapor Distribution Systems
 4.2 - Placing Vapor Distribution Systems and Appliances into Operation
Topic CETP-2014 Check

Reference (If Applicable)
5.1 - Basic Bulk Plant
5.1.1 - Bulk Storage Container BPP–7-1
5.1.2 - Loading a CTMV (Bobtail/Transport)
Using a Plant Pump BDO–3-2
5.1.3 - Loading a CTMV (Bobtail/Transport) BDO–3-3
Using a Plant Vapor Compressor
5.1.4 - Unloading a CTMV (Bobtail/Transport) BDO – 5 (ALL)
5.1.5 - Unloading a Railcar 3.6 & 3.7 – 5

(ALL)
5.1.6 - Preparing & Transporting DOT PDO-7 (ALL)
Cylinders PDO-9-1&2
5.1.7 - Preparing & Transporting ASME 4.1 – 4-1
Containers -
5.1.8 - Evacuating LP-Gas from Containers BPO – 6-5
5.1.9 - Purging Containers PDO-7-3

5.1.10 - Dispensing LP-Gas in a Bulk Plant PDO-8-2
5.2 - Vapor Distribution Systems 4.1 & 4.2 -
21
Procedures
5.1 Bulk Plant Operating Procedures
Proper Personal Protective Equipment (PPE) should be worn when applicable. Check your
company policy for specific PPE required.
5.1.1 Bulk Storage Containers
Startup
1. Before beginning any operation make sure the transfer equipment is in good
condition, the bulk storage container is safe to be filled, and the surrounding
area is free from hazards that may constitute a source of ignition.
2. Check to see that all the appropriate manual valves (i.e., globe, angle, or ball)
are open on the bulk storage containers.
3. If the container has manually operated internal valves, make sure that the
emergency shutdown system is operational and that internal valves are
opened.
a. Pneumatically operated systems – Check to see that there is

adequate pressure (typically, 30-70 psig) and that the system is leak
free.
b. Cable operated systems – Check to see that all cables are

operational.
Operation
1. Now the system is operational and is ready to:
a. Fill a Cargo Tank Motor Vehicle (CTMV), more commonly referred to

as a “bobtail” or “transport” – see subsections 5.1.2 and 5.1.3
b. Unload a CTMV (bobtail or transport) – see subsection 5.1.4
c. Unload a Railcar – see subsection 5.1.5
d. Fill Containers/Cylinders – see subsections 5.1.6 and 5.1.7
e. Evacuate Cylinders – see subsection 5.1.8
22
Procedures
Shutdown
1. Check to see that all the appropriate manual valves (i.e., globe, angle, or ball)
are closed on the bulk storage containers.
2. If the container has remotely operated internal valves, make sure that these
valves are closed by releasing the pressure in emergency shutdown system
or by pulling the cable for the system.
5.1.2 Loading a Cargo Tank Motor Vehicle (CTMV) Using a Plant Pump
Before the filling operation, the person loading the CTMV (bobtail or transport) should be
familiar with the bulk plant layout and operating procedures.
1. Prepare for the loading operation

2. Check the liquid level gauges
3. Check to see valves are closed and inspect hoses
4. Connect the transfer hoses
5. Perform the sniff test
6. Fill the cargo tank
7. Disconnect hoses and prepare the bobtail for travel
Step 1: Prepare for the Loading Operation
When you first arrive at the bulk plant to load your bobtail:
• Check for hazards that might create an unsafe filling condition.
• Check to see that the liquid fill connection on the cargo tank is at least 10 ft from the
nearest bulk storage container. Always contact your supervisor to determine how to
position your bobtail at the bulkhead in a way that maximizes the shearing effect of the
hoses and piping in the event of a pull-away.
• Set the parking brake and turn off the engine.
• Chock blocks or wheel stops are required in front of and behind a rear wheel to prevent
the vehicle from rolling forward or backward.
• Remove any ignition sources within 25 ft of the transfer point. Shut down any internal
combustion engines within 15 ft of the transfer. Cease metal working operations
(grinding, welding, brazing, etc.) within 35 ft of the point of transfer.
Smoking, open flame, portable electrical tools, and extension

lights capable of igniting LP-gas shall not be permitted within 25 ft
of a point of transfer while filling operations are in progress. In
addition, metal cutting, grinding, brazing, soldering or welding
shall not be permitted within 35 ft. of a point of transfer while filling
operations are in progress.
23
Procedures
Step 2: Check the Liquid Level Gauges

• Check the liquid level gauges on the bulk plant storage tank to make sure that it has
enough liquid propane to fill your cargo tank. If it does not, contact your supervisor or
plant manager so they can set up delivery.
• Check the liquid level gauges on your cargo tank and record how much propane is in the
tank before beginning the load operation.
Step 3: Make sure Valves are Closed and Check Hoses
Before connecting the hoses to begin loading operations, you must make sure all appropriate
valves are closed and hoses are in good working condition.
• Make sure the liquid fill and vapor equalizing valves on the cargo tank are closed.
• Remove the dust caps from the valves, inspect them for damage and wear, and if
necessary, replace defective gaskets.
• Make sure the bulk plant liquid and vapor hose-end valves are closed.
• Inspect the transfer hoses, couplings, valves, and connectors, including ACME threads,
to make sure they are free of defects or damage.
Step 4: Connect the Transfer Hoses
To properly connect the liquid transfer and vapor equalizing hoses:
• Connect the plant liquid hose to the liquid fill valve on the bobtail cargo tank. Whenever
handling the hose, be sure to point the end of the hose away from your body.
• Tighten the plant liquid hose into the filler valve of the cargo tank by moving the hose
assembly up and down while turning the ACME connector. Once the connection is hand
tight, give it an additional quarter turn using a spanner wrench.
• Connect the vapor equalizing hose between the storage container and the cargo tank
and hand tighten so it doesn’t leak.
NOTE: In accordance with company policy, operate the ESVs at the loading bulkhead to be
sure they are functioning properly. If they are not operating properly, do not connect the
transfer hoses between the storage container and the cargo tank on the bulk delivery
vehicle.
Step 5: Perform the Sniff Test
Before filling the cargo tank, your company may require you to perform a sniff test and verify
product odorization.
To do this:
• Vent a small quantity of propane through the vent valve located on the plant liquid hose.
• Sniff the area immediately after the liquid vaporizes.
• If you can smell propane odorant, proceed with the loading operation.
24
Procedures
• If you cannot smell propane odorant or smell anything unusual, do not load the cargo
tank. Contact your supervisor immediately and tell others in the area not to load until
approved by the facility manager or supervisor.
Step 6: Fill the Cargo Tank
During the transfer operation, a qualified person must be in attendance at all times. This means
that you must be within 25 ft of the cargo tank and have an unobstructed view of it in order to
monitor the condition of the transfer operation, and handle any emergencies.
To fill the cargo tank:

• Insert a ticket in the plant meter and reset the register to zero if applicable.
• Check to see that all liquid and vapor equalizing valves are fully open in the transfer
piping between the plant storage tanks and the bulkhead.
• Open the manual vapor equalizing valve and the manual filling valve on the cargo tank.
If you notice any leaks, close all valves, stop the process, and repair leaks before
proceeding.
• Start the pump and monitor the liquid level gauges. When the maximum permitted filling
level is reached, immediately turn off the plant pump.
• Close the plant liquid hose valve and all valves on the cargo tank.
Be alert for signs of erratic pump operation during the transfer. If a leak or
fire develops during the transfer, close all ESVs immediately and stop the
pump, if you can do so safely. Move upwind and away from any
uncontrolled release of propane.
Step 7: Disconnect Hoses and Prepare Bobtail for Travel
When the loading operation is complete, do the following to prepare the bobtail for
travel:
• Bleed down and disconnect the plant liquid hose from the bobtail liquid fill connection.
• Bleed down and disconnect the vapor equalizing hose from the vapor equalizing
connection on the bobtail.
• Replace the dust caps on the bobtail liquid fill and vapor equalizing connections.
• Replace the dust caps on the plant liquid and vapor hoses and store them as required.
• Walk around the bobtail and check for any obstacles that may be in its path.
• Remove the chock blocks and stow them in their travel compartment or holders.
• Move the vehicle, but only after it has been determined the path is clear and the
discharge of propane has dissipated.
25
Procedures
5.1.3 Loading a Cargo Tank Motor Vehicle (CTMV) Using a Plant Compressor
Identifying Steps for Propane Transfer Using the Plant Compressor to Fill the Bobtail
Note: Procedures for filling bobtails are based on practices commonly used in the propane
industry, manufacturers’ instructions, and provisions in NFPA 58. Before the filling operation, be
sure to see your supervisor for a copy of your plant layout, including bulk plant equipment,
piping functions, and company operating procedures.
Step 1:
Position the bobtail.
• Position the bobtail at the loading bulkhead, with the fill connection on the cargo tank at
least 10 feet from the nearest bulk storage container.
• Set the vehicle parking brake.
• Shut down the engine.
• Place chock blocks in front and behind a rear wheel to prevent movement of the vehicle.
Step 2:
Examine the plant piping and flow control valves.
Determine how vapor will move from the cargo tank to the suction side of the
compressor and on to the bulk storage tank(s).
Step 3:
Set the liquid level gauges on the bobtail.
• Before connecting the hoses from the bulk propane storage tank to the bobtail,
determine the maximum permitted filling level. This is determined by obtaining the
specific gravity of your propane from shipping papers and observing the liquid propane
temperature on the thermometer located either in the cargo tank or in the storage
container at the plant.
• When a storage container is filled by volume, the filling stops when the volume of the
liquid inside the container reaches a certain percent of the container’s water capacity.
The maximum permitted volume is indicated by a fixed maximum liquid level gauge. The
gauge extends inside the container and measures the level of the liquid. The gauges
most often used on bobtails are the fixed maximum liquid level gauge and the variable
liquid level gauge.
If either the temperature or the specific gravity is not known, the float gauge cannot be
used to determine the correct set point and therefore, the maximum permitted filling level
of the cargo tank cannot be determined. In that case, the fixed maximum liquid level
gauge must be used to determine the maximum filling level.
26
Procedures
Step 4:
Inspect the compressor and check the crankcase oil level in the sight glass, or by using the
dipstick
Step 5:
Connect the liquid fill and compressor vapor hoses to fill the cargo tank.
• Before connecting the transfer hoses, make sure all sources of ignition within 25 ft of the
transfer point are removed. Internal combustion engines within 15 ft of the point of
transfer must be shut down while transfer operations are in progress, with exceptions as
listed in NFPA 58. Cease metal working operations (grinding, welding, brazing, etc.)
within 35 ft of the point of transfer.
• Carefully inspect the liquid and vapor transfer hose assemblies. If any defect is found,
discontinue the operation, notify your supervisor and do not resume loading until the
hose defect has been eliminated. If another loading bulkhead is available, move to it
after notifying your supervisor and ensuring that a warning notice is placed on the
defective hose.
• Check to see that the fill and vapor equalizing valves on the bobtail are closed. Remove
the dust covers from the valve connectors. Inspect the valve connectors for damage and
wear and if necessary, replace any defective O-ring or flat gasket.
• Check to see that the liquid and vapor hose-end valves are closed. In accordance with
company policy, operate the emergency shut-down valves (ESVs) at the loading
bulkhead to be sure they are functioning properly. CAUTION: If the ESV’s do not operate
properly, do not connect the transfer hoses.
• Connect the liquid plant hose-end valve to the fill valve on the bobtail. Carry it in the
palm of your hand pointed away from your body. Tighten the plant hose-end valve into
the filler valve of the bobtail by gently moving the hose-end valve up and down while
turning the ACME connector. Once the connector is hand-tight, turn the connector an
additional 1/8 to 1/4 turn using a spanner wrench, tapping the handle of the spanner
wrench with the palm of a gloved-hand.
• Slightly open the liquid hose-end valve and check for leakage. If leakage exists, close
the hose-end valve and disconnect the ACME adapter after the connection has bled
down and is de-pressurized. Examine the condition of the O-ring or flat gasket in the
cargo tank filler adapter and replace as needed.
• Examine the ACME threads on the hose-end adapter and the bobtail filler connection. If
either is excessively worn so the connection leaks with a new O-ring or gasket, replace
the worn fitting or adapter before proceeding with the loading operation.
• Connect the vapor equalizing hose between the storage container and the bobtail.
Follow the procedures used when connecting the plant liquid transfer hose with the
exception of the use of the spanner wrench.
Step 6:
Sniff test to verify propane odorization.
27
Procedures
Step 7:
Open the vent on the compressor’s liquid trap to verify that liquid is not present in the vapor
hose and suction line; it may severely damage the compressor and ultimately produce leaks at
the head gasket or oil sump.
Step 8:
Verify the 4-way valve is in the proper position for loading the bobtail and check all in-line valves
and bulk tank valves for their proper open or closed position.
Step 9:
Check to see that all shutoff valves are open in the liquid transfer, vapor suction and vapor
discharge lines.
Step 10:
Start the compressor in accordance with manufacturer’s instructions.
• Vapor compressors remove vapor from the receiving tank, compress the vapor to a
higher pressure, and move it through piping into the supply tank. The higher pressure
vapor in the supply tank forces liquid to move to the receiving tank where the pressure
has been reduced by the action of the vapor compressor.
Step 11:
Verify the proper filling limit set for the cargo tank, using the thermometer reading and the liquid
level gauge index.
Step 12:
Monitor the cargo tank filling and stop the compressor when the proper liquid level is reached,
or if any abnormal operating condition is noticed.
Step 13:
Close all valves in the transfer hoses.
Step 14:
Close all valves in both the suction and discharge vapor piping circuits. Close the ESV(s) at the
transfer bulkhead and the appropriate liquid and vapor valves in the bulk storage tank(s), if
applicable.
28
Procedures
Step 15:
Disconnect the transfer hoses and prepare the bobtail for travel.
• Bleed down the gas trapped between the cargo tank filler valve and the transfer hose-
end valve and disconnect the liquid hose from the Bobtail fill valve.
• Bleed down the gas trapped between the vapor return valve and the vapor equaling
hose-end valve and disconnect the vapor hose from the vapor equalizing valve on the
bobtail.
• Replace the dust caps on the fill and vapor equalizing valves.
• Replace the dust caps on the liquid and vapor hose-end valves. Store the hoses as
required.
• If applicable, stamp or print the loading ticket.
• Fill out any company inventory forms and process them as required.
• Before removing the chock blocks, walk around the Bobtail and check for any obstacles
that may be in its path.
• Move the truck only after it has been determined the path is clear and any discharge of
propane has dissipated.
• If for any reason the transfer operation is interrupted, or the attendant must leave the
area, the compressor must be shutdown and transfer hoses disconnected as outlined in
steps (12)-(14). DO NOT leave transfer hoses connected to a Bobtail while unattended.
Be sure you know:
• Your company’s policies and standard operating procedures.

• How to conduct transfer operations following your company’s procedures.
• How to react in the event of an abnormal operating condition or emergency.
29
Procedures
5.1.4 Unloading a Cargo Tank Motor Vehicle
Procedures for liquid transfer operations at LP-Gas bulk storage tanks from transports are
based on common industry practices, manufacturer’s instructions, provisions listed in NFPA 58-
2014 and U. S. Department of Transportation (DOT) cargo tank unloading regulations.
Furthermore, the major steps in the unloading procedures will vary according to the emergency
discharge system used on the CTMV.
These procedures are designed to be as universal as possible, and are to be used as a guide
only. They do not replace company policies or federal, state and local codes. Be sure to check
company policy and state and local codes before beginning the unloading operation. Before
performing the unloading operation, you should review bulk plant layout and operating
procedures. Make sure you are familiar with the bulk plant equipment, piping functions, and
company operating procedures.
US Department of Transportation Requirements
U.S. DOT requirements for drivers and operators unloading cargo tank motor
vehicles (CTMV) are set out in several sections of the Code of Federal
Regulations. The principal requirements can be found in the following
references:
• Unloading Attendance Requirements – 49 CFR 177.834
• CTMV Safety Check – 49 CFR 177.840(m)
• Unloading Procedures* – 49 CFR 177.840 (q)
• Emergency Discharge Control – 49 CFR 178.337-11, 173.315(n)
* for cargo tanks with capacities larger than 3500 water gallons, and
cargo tanks in other than metered delivery service
US DOT unloading rules include:
1. A qualified person must be in attendance at all times during unloading.
2. A person is ”qualified'' if he or she has been made aware of the nature of

the hazardous material which is to be loaded or unloaded, has been
instructed on the procedures to be followed in emergencies, is authorized
to move the cargo tank, and has the means to do so.
3. The qualified person attending the unloading operation must be alert and
remain within 25 feet of the cargo tank when the CTMV internal self-
closing stop valve is open.
30
Procedures
4. The qualified person attending the unloading operation must have an

unobstructed view of the cargo tank and delivery hose to the maximum
extent practicable, except during short periods when it is necessary to
activate controls or monitor the receiving container.
New transport cargo tanks placed into service after July 1, 2001, must be
equipped with either a passive emergency shutdown system or, if the transport is
used in metered delivery service, a remote (radio frequency) shutdown system
with a query feature for unloading operations lasting more than 5 minutes. Cargo
tanks that are used in both metered and non-metered service must have both
types of emergency shutdown systems.
Startup
1. Inspect the transfer area, before giving the driver the signal to enter the plant
area.
2. Spot the CTMV (most commonly, a “transport”) and guide it into position at
the unloading bulkhead. To prevent unnecessary wear on the PTO (power
take-off) drive shaft and the pump during unloading, the centerlines of the
tractor and trailer should coincide.
3. Set the brakes and turn off all electrical devices.
4. Place chock blocks or wheel stops at the front and back of one of the tractor
drive wheels.
5. If applicable, check with company policy for procedures to follow if a water or

ammonia test is required.
31
Procedures
Operation
1. Determine the maximum amount of LP-Gas to be transferred to the plant

storage tanks. In most cases, a transport will arrive only when there is
enough room in the plant storage tank(s) for the entire load of LP-Gas. To
avoid accidentally overfilling the storage tank(s), calculate the maximum
amount of LP-Gas that can be added safely.
2. Review and follow company procedures for checking the operation of the
ESVs and pull-a-way protection installed in the plant. If the ESVs will not
operate properly, do not continue the transfer operation. Notify the bulk
plant’s manager or supervisor.
3. Check the manual shutoff valves on the transport liquid and vapor
connections to be sure they are fully closed. Slowly remove the dust caps.
4. Remove the dust caps from the connectors on the transfer hoses. Check the
connectors to be sure they are clean. Check the O-rings on the valve
connectors to be sure they are in good condition. If necessary, clean the
connectors with a rag and replace worn, flattened, or damaged O-rings
before making connections to be transport.
5. Conduct a visual inspection of delivery hose deployed during each unloading

operation. Rejection criteria include exposed reinforcement, permanently
deformed wire braid reinforcement, soft spots, bulging, loose outer covering,
damaged couplings, and loose/missing/corroded bolts.
6. Connect hoses between the transport and the bulkhead. When using ACME
connectors, spin on the connectors until they are hand-tight. While tightening
the connectors, move the hose or hose end valve up and down slightly to
prevent the threads from seizing. When each connection is hand-tight,
tighten it to “wrench tight” with a spanner wrench. Never bang on the
connector with the dust cap, a hammer, or other device.
7. Check each connection for leaks by isolating it from the system and charging
it with LP-Gas. If any connection leaks, close all valves and retighten the
connection. If the leak persists, examine the condition of connection o-rings
or gaskets, and replace them if they are defective.
Do not transfer liquid if leaking LP-Gas is present.
8. Verify that the LP-Gas being delivered to the bulk plant is odorized by
conducting a sniff test or other means, and document the results.
32
Procedures
9. When all valves are fully open, start the pump by engaging the PTO. Listen
carefully for sounds of erratic pump behavior and check the sight gauge or
flow indicator to be sure liquid is flowing through the system.
[Note: If an excess-flow valve slugs shut, stop the pump; then, reopen the
excess-flow valve by equalizing pressure across the valve before continuing.]
10. Unload the transport tank. Remember that a qualified person must be
present during the entire transfer operation to handle emergencies and
monitor the condition of the transfer system. Monitor the liquid level gauges
in the plant storage tanks carefully during the operation. If possible, equalize
pressure between the transport and the plant storage tank.
11. When a tank reaches its maximum permitted filling level, stop the pump and
adjust the valves in the plant piping to route the remainder of the load to
another tank.
Shutdown
1. When the plant storage tank reaches its maximum permitted filling level or
the transport tank is empty, stop the pump and immediately close all liquid
and vapor lines involved in the transfer operation.
2. Bleed down and disconnect the hoses. Store them away as necessary.
Caution: Never disconnect any hose until the LP-Gas trapped in the
connection has been safely bled off. This should be done through
either the bleeder valve on the hose-end valve or a pipe-away
adaptor in the transport or bulkhead connections.
3. Replace all caps on hose-end valves and on transport and plant liquid and
vapor connections.
4. Complete the plant unloading form, any necessary accounting forms, and the
return bill of lading.
5. Check to be sure that all bulkhead or transport hoses have been

disconnected and securely stored and that all valves are tightly closed and
capped.
6. Before removing the chock blocks, walk around the CTMV and check for any
obstacles that may be in its path. When determined to be clear, remove the
chock blocks and store them on the vehicle.
7. Move the truck only after it has been determined the path is clear and any
discharge of LP-Gas has dissipated.
33
Procedures
5.1.5 Unloading a LP-Gas Railcar Using the Plant Compressor
Procedures for liquid transfer operations at LP-Gas bulk storage tanks from a
railcar are based on common industry practices, manufacturer’s instructions, and
provisions listed in NFPA 58 and U.S. DOT regulations. These procedures are
designed to be as universal as possible, and are to be used as a guide only.
They do not replace company policies or federal, state and local codes. Check
company policy and state and local codes before beginning the unloading
operation.
Before the unloading operation, you should review bulk plant layout and
operating procedures. Make sure you are familiar with the bulk plant equipment,
piping functions, and company operating procedures.
US Department of Transportation Requirements
DOT regulations require employers to train and test every employee directly
involved in the transportation of hazardous materials, including personnel who
inspect, load or unload pressurized railcars used in LP-Gas transportation.
Some specific regulations that are relevant include:
• Use of Tank Cars - 49 CFR 173.31
• Qualification and Maintenance of Tank Cars – 49 CFR 180, Subpart F
• Training - 49 CFR 172, Subpart H
• Attendance during product transfer—49 CFR 174.67
• Safety and Security Plans – 49 CFR 172, Subpart I
• Carriage By Rail - 49 CFR Part 174, Subparts A through D
• Quality Assurance Program - 49 CFR 179.7
Other regulations or standards adopted by reference that may apply include:
• Association of American Railroads, Manual of Standards and

Recommended Practices, Section C, Part III, Specifications for Tank Cars
(M-1002)
• Association of American Railroads, Field Manual of the Interchange

Rules, (#70, 88, 89, and 90)
34
Procedures
• Canadian General Standards Board, CAN/CGSB 43.147-2005,

Construction, Modification, Qualification, Maintenance and Selection and
Use of Means of Containment for the Handling, Offering for Transport, or
Transporting of Dangerous Goods by Rail
Startup
1. Check to make sure that the following conditions exist:
• Railcar wheels are chocked.

• Railcar handbrake is set.
• Derailer is set to the derailing position or siding switch is locked to
prevent access to spur.
• Railcar and spur entrance(s) are flagged (including Blue and White
“STOP - TANK CAR CONNECTED” sign).
2. Climb the unloading riser and lower the platform to gain access to the dome
and tank car openings.
3. Be sure the platform is properly seated and secured before crossing over to
the tank car. Exercise caution when climbing or working on the riser,
especially in wet or icy weather.
4. Before opening the dome, be sure that all sources of ignition have been
removed from the area as outlined in Section 4. Also, avoid creating sparks
when opening or working in the dome.
Caution: If one of the fittings is leaking, the dome might be filled with
LP-Gas vapor.
5. Put on Personal Protective Equipment.
6. Inspect the rail car for:

• Shipping name of product -2 sides
• Reporting markings – 4 sides
• Tank Car Classification – 2 sides
• Safety valves and tank test information – 2 sides
• Placarding – 4 sides
• All valves closed
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Procedures
• All valves plugged and wrench tight

• Valves free of corrosion
• Bolts and nuts present and secure
• Protective valve housing secure
• No corrosion or damage on relief valve.
7. If the inspection reveals an unsafe condition that cannot be corrected, notify

the bulk plant manager or supervisor. In most cases, a “bad order” tag must
be filled out to notify the shipper of the problem.
8. Rail Car contents must be verified with Shipping Paper before making hose
connections.
9. Gauge the contents of the railcar by using the slip tube gauge. First, open
the bleeder valve at the top of the gauge and raise or lower the tube until a
white plume of mist vents out of the bleeder orifice indicating that the slip tube
is in contact with liquid LP-Gas. A series of graduated markings on the slip
tube indicates the distance in inches and feet from the top of the tank to the
surface of the liquid, also known as the "outage" of the railcar.
The slip tube is always under high pressure and can cause serious
injuries if it springs up quickly or unexpectedly. Therefore, always
exercise caution when working around the slip tube gauge by
standing to the side of the slip tube gauge before releasing the brake
or safety catch.
10. Once the outage of the railcar is read, convert the outage to gallons by using
the outage table (sometimes called a “strapping chart”) furnished by the
shipper or railcar manufacturer.
Even a relatively small error in reading the slip tube gauge can make
a large difference in calculating the number of gallons in the tank.
Therefore, it is important to measure the railcar outage at least twice
to be sure of getting an accurate reading.
11. Determine the maximum amount of LP-Gas that can be transferred to the
plant bulk storage tanks. To avoid accidentally overfilling the tank, calculate
the maximum amount of LP-Gas that can be safely added.
Even if the plant has more than one storage tank, determine how much LP-
Gas can be safely added to each tank. If a single tank will not hold the entire
load, use calculations to distribute the load and notify the bulk plant manager
36
Procedures
or supervisor.
Gauge the contents of the plant storage tank with the rotary or float gauge
installed in the tank head. Record the reading on the company form or on a
worksheet.
If there is more LP-Gas in the railcar than the plant tank(s) will hold safely,
notify the bulk plant manager or supervisor.
Figure 5.1.5a – Typical Railcar Riser with ESVs
12. Before connecting the liquid and vapor transfer hoses between the railcar and
the unloading riser check the manual shutoff valves on the railcar liquid and
vapor connections to make sure they are fully closed. Then, carefully remove
the plugs.
LP-Gas may vent around the plug threads for a short time. Wear
safety gloves throughout the operation. Keep face and other parts
of the body away from the valve opening. If LP-Gas continues to
vent around the plug threads, the manual shutoff valve may be
faulty. Retighten the plug and notify the bulk plant manager or
supervisor.
13. Install the ESVs in the liquid and vapor valves. It may be necessary to install
stubs (schedule 80 pipe nipples) before installing the ESVs. Thread the
ESVs into the valve opening until they are hand tight. Then, tighten them
37
Procedures
with the appropriate wrench until they are securely seated. Once installed,
open the ESVs in accordance with company procedures.
14. Remove the dust caps from the connectors on the riser hoses. Check the
connectors to be sure they are clean. Check the O-rings on the ESV or
unloading stub to be sure they are in good condition. If necessary, clean the
connectors with a rag and replace worn, flattened, or damaged O-rings.
15. Connect the hoses to the railcar stubs or ESVs (whichever is applicable) by
spinning on the ACME connectors until they are hand tight. As the
connectors are tightened, move the hose or hose-end valve up and down
slightly to prevent the thread from seizing. When each connection is hand
tight, tighten it an additional 1/8 turn with a spanner wrench.
16. Check the ESVs at the riser by opening and closing them according to plant
test procedures. Be sure the remote operators are working properly and that
all fusible links are intact. If the ESVs will not operate properly, do not
continue the transfer operation. If possible, correct the problem. Otherwise,
notify the bulk plant manager or supervisor.
17. Check each connection for leaks by opening and closing the manual shutoff
valve at the railcar to charge the connection with LP-Gas.
18. If using ESVs instead of unloading stubs, open the ESV to charge and test
the hose connection. If there are any connection leaks, close all valves and
retighten the connection. If the leak continues, notify the bulk plant manager
or supervisor.
Operation
A qualified person must be present at all times during the entire transfer
operation to monitor the condition of the transfer system and to handle
emergencies. Otherwise, the operation must be shut down and hoses
disconnected.
If a release or fire develops at any time during the operation, close all ESVs
immediately and stop the compressor. Refer to Section 3 of this handbook and
company procedures to address the situation.
Be alert for signs of erratic compressor operation. If a problem develops, shut

down the operation and correct it before continuing.
1. Open the vapor valves at the railcar riser. Then, open all valves in the liquid
line, starting at the manual shutoff valves on the railcar and working toward
the plant storage tank(s). Allow as much liquid as possible to drift between
the two tanks. Open the remaining valves in the vapor line. Open all valves
38
Procedures
slowly to prevent the excess-flow valves from slugging.
2. Check to be sure the four-way valve and the plant valves have been set so
that the compressor will remove vapor from the plant storage tank and
discharge it into the railcar. Figures 5.1.5b and 5.1.5c illustrate the
compressor 4-way valve and piping positions for unloading in a typical bulk
plant. Plant piping might vary. Verify the proper valve positions and
operating procedures for each bulk plant.
Figure 5.1.5b Figure 5.1.5c

Compressor & Bulk Plant
Connections and Valves 4-Way Valve Positions
Operation of Valves for Cargo Tank Unloading
4-Way Valve Valve A Valve B Valve C

Position One Open Open Close
3. Open the vent on the compressor’s liquid trap to verify that liquid is not
present in the vapor hose and suction line. Liquid may severely damage the
compressor and ultimately produce leaks at the head gasket or oil sump.
4. Start the compressor and check the pressure gauges for excessively high
exhaust or excessively low intake pressure. If either occurs, stop the
compressor and correct the problem before continuing. Check the sight glass
or flow indicator to make sure liquid is flowing through the system.
5. When the plant storage tank reaches its maximum permitted filling level or
the railcar is empty, close all valves in the liquid line and stop the
compressor.
6. Reverse the four-way valve and adjust the plant piping manifold so the
compressor will withdraw vapor from the railcar and force it through the liquid
space of the plant storage tank (refer to Figures 5.1.5b and 5.1.5c). Restart
39
Procedures
the compressor and check the pressure gauges for excessively high
discharge or excessively low intake pressure. If either occurs, shut down the
compressor and correct the problem before continuing.
Operation of Valves for Cargo Tank Vapor Recovery
4-Way Valve Valve A Valve B Valve C

Position Two Close Open Open
Shutdown
1. At the end of the vapor recovery operation, close all valves in the vapor line
and shut down the compressor.
[Note: Some plants shut down the compressor when the discharge pressure
rises to four times the intake pressure. Others stop vapor recovery
operations when the intake pressure drops to 50 psi in the summer or 30 psi
in the winter. Under some conditions plants will also shut down their
compressors, if the intake pressure drops less than 10 psi during 15 minutes
of operations. Check with your supervisor for the proper guidelines to follow.]
2. To make sure that the railcar is totally unloaded, open the sampling valve. If
liquid escapes, it might not be fully unloaded. Resume unloading operations
until the railcar is totally unloaded.
3. Close all railcar discharge valves, ESVs, and transfer hose-end valves.
4. Vent the LP-Gas trapped between valves, stubs and hose couplings. When
the connections are fully de-pressurized, disconnect the transfer hoses.
5. Remove the railcar unloading nipples (or “stubs”) that are screwed into the
railcar valve outlets.
6. Replace all railcar valves openings and tighten as appropriate.
7. Replace and secure all covers over fittings.
8. Check to be sure there is no liquid left in the railcar by partially opening the
sampling valve.
9. Bleed down and disconnect the hoses at the riser. Never disconnect any
hose until the LP-Gas trapped in the connection has been safely bled off.
10. Replace all dust caps and store the hoses.
40
Procedures
11. Remove the unloading stubs or ESVs from the railcar, and replace the plugs
in the liquid and vapor valve openings.
12. If any railcar defects were found during the unloading operation, complete a
“Bad Order Tag” (see Figure 5.1.5d) and attach it to one of the sampling
valves.
Figure 5.1.5d - “Bad Order Tag”
13. Lower the dome cover and secure it appropriately.
14. Stow all transfer hoses and fittings and raise the unloading riser platform to
its stored position.
15. Remove and store the warning signs, chock blocks and reset the derail from
the derailing position.
Do not release the hand brake on the railcar. This will be done by
railroad personnel when the railcar is picked up.
16. Prior to releasing for return shipment verify the following:

• Shipping name of product – 2 sides
• Reporting markings – 4 sides
• Tank Car Classification – 2 sides
• Safety valve and tank test information -2 sides
• Placarding – 4 sides
• All valves closed
• All valves plugged and wrench tight
• Empty Tank Car Return Billing instructions completed
• Valves free of corrosion
• Bolts and nuts present and secure
• Protective valve housing secure
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Procedures
• No corrosion or damage visible on relief valve.
17. Take an extra look around the railcar and unloading site to make sure
everything is safe and secure.
CAUTION: Whether loaded or unloaded, a railcar is

hazardous. Unless it has been thoroughly purged and
cleaned, all safety and hazardous materials handling
regulations must be observed.
18. Complete a Railcar Return Instructions Form and deliver the form to the rail
carrier representative (see sample form in Figure 5.1.5e). This form must be
prepared, signed and presented to the rail carrier representative for their
signature before the railcar is released.
The LP-Gas marketer should use reasonable care to provide

a safe and secure environment for the railcar, from the time
the railcar return form is used to notify the railroad company
agent that the car is ready to be picked up until the time it is
actually removed from the siding.
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Procedures
Figure 5.1.5e - Sample Railcar Return Instructions Form
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Procedures
5.1.6 Preparation and Transportation of DOT Cylinders
This section provides general guidance for the preparation of DOT cylinders
being shipped from a bulk plant. For complete details and procedures that fully
describe the associated regulatory requirements, refer to 49 CFR 173, the
Compressed Gas Association publication CGA-6 (Standard for Visual Inspection
of Steel Compressed Gas Cylinders, 1993), CFR 49 section 180 subpart c
(Requalification and maintenance of packaging) and ANSI/CGA C-6.3
(Guidelines for Visual Inspection and Requalification of Low Pressure Aluminum
Compressed Gas Cylinders, 1991).
Cylinder Inspection
Prior to filling cylinders at the bulk plant, cylinders that have been in service must
be inspected to determine their fitness for continued service. Specifically, DOT
regulations stipulate that no individual is allowed to fill a cylinder that is overdue
for periodic requalification with a hazardous material and then offer it for
transportation.
Before each filling of a cylinder, the individual filling the cylinder must visually
inspect the outside of the cylinder. Cylinders sleeves must be removed to
facilitate the exterior visual inspection. A cylinder that has any of the following
characteristics cannot be filled and offered for transportation:
• A crack or leak.
• Bulging.
• A defective valve.
• A leaking or defective pressure relief device.
• Evidence of physical abuse.
• Fire or heat damage.
• Detrimental rusting or corrosion.
Requalification of Cylinders
Any cylinder that is due for requalification cannot be refilled and offered for
transportation until it is requalified using methods prescribed by DOT. In
jurisdictions that have adopted NFPA 58-2001 (without exceptions or
modifications to §2.2.1.5), there is no distinction between cylinders that are
transported in commerce and those that are not with respect to the cylinder
requalification requirement. Beginning with the 2004 edition, cylinders that are in
stationary service and filled on-site are permitted to undergo a visual inspection
(§5.2.3) instead of requalification.
Specific to requalification requirements, all cylinders received at a bulk plant must

be checked for:
44
Procedures
Requalification Methods
There are three ways to requalify a cylinder. The specific method used is
indicated on the date stamped on each cylinder.
• Hydrostatic Test—A date without a letter indicates the cylinder was

subjected to a complete water jacket hydrostatic test. The next
requalification must be within 12 years.
• Proof Pressure Test—A date followed by the letter “S” indicates a proof
pressure test has been performed. The next requalification must be within
7 years.
• External Visual Inspection (CGA Inspection Method)—A date followed by
the letter “E” indicates a recorded external visual inspection was
performed. The next requalification must be within 5 years.
Requalification Due Date
Three requalification methods are used to verify DOT cylinder fitness for
continued service. The method used determines when the cylinder is next
due for requalification.
Requalification date markings consist of numbers designating the month and

year of the last requalification, followed by a letter or blank to signify the
requalification method used (see Table 5.1.6a).
Letter After Next Requalification Due

Requalification Method
Year Stamp (years)
None Volumetric Expansion Test 12
S Proof Pressure Test 7
External Visual Inspection
E 5
(CGA Inspection Method)
Table 5.1.6a - DOT Cylinder Requalification Periods
For example, a DOT cylinder marked 10 11E is due for requalification

before or during October 2016. The cylinder may require requalification
before its due dates if it is damaged or subjected to physical abuse,
excessive corrosion or heat. Cylinders that have been exposed to fire
must be immediately removed from service.
A Requalification Identification Number (RIN) also appears with the

Requalification Date. The RIN will be either a 4 character or 7 character
RIN consisting of letters and numbers.
o The 4 character RIN will have a letter and a number above the
Requalification Date and 2 numbers under the Requalification
45
Procedures
Date, as shown below.
A1
05 04 x
32
Where:
“05” is the month of requalification;
“A123” is the RIN;
“04” is the year of requalification
(2004);
“X” represents the symbols
described in paragraphs (f)(2)
through (f)(7) of 49 CFR 180.213.
{Note: Characters not to scale in
size.}
o The 7 character RIN will appear as a letter and 6 numbers all

appearing either over, under or before the Requalification Date
(see examples below).
V100001
0504 E -or-
0504 E
V100001 -or-
V100001 0504 E
Where:“V10001” is the RIN; “0504” i

the month and year of requalification
“E” represents external visual
inspection.
• Components to Check for Continued Service
o Proper cylinder valve protection

o Filler valves and weather caps
o Valve hand-wheels
o Valve stem leaks
o Relief valves
o Quick-closing couplings on motor fuel cylinders
o Fixed maximum liquid level gauge
o Float gauges
o Foot rings and welds
o Evidence of ammonia contamination
o Any abnormal conditions reported by the customer
46
Procedures
If valve or fitting replacement is necessary, or requalification is required, the cylinder

should be moved to a designated area for that purpose.
Only facilities with a Requalification Identification Number issued by the Pipeline and
Hazardous Materials Safety Administration are allowed to perform a DOT specification
cylinder requalification. Check with your supervisor.
Safety Considerations for Storing and Processing DOT Cylinders
Cylinders should be arranged so that any cylinder can be accessed in the event
of a service valve or other leak. Proper valve protection should be maintained at
all times. Also, cylinders should be stored so that cylinder relief valve discharges
are not directed at the service valves of adjacent cylinders in order to limit the
extent of damage and the hazards to persons and property in the event of a relief
valve discharge and fire.
Checking for Proper Cylinder Labeling
Cylinders that contain LP-Gas should be labeled to indicate their contents in

compliance with DOT hazardous material transportation regulations (see Figure
5.1.6a). Cylinders may be checked for proper labeling as part of the inspection
process.
LIQUEFIED
PETROLEUM
GAS
UN 1075
Figure 5.1.6a – DOT Label
47
Procedures
New Cylinder Inspection

When new DOT cylinders arrive, they should be inspected to make sure that they
are not damaged and are acceptable for LP-Gas service. Important items to
check are:
• DOT and NFPA 58 required markings

• Proper DOT Specification and Service Pressure (minimum 240 psig)
• Tare Weight
• Water Capacity
• Manufacturer Name or Mark and Serial Number
• Manufacturer Test Date
• Relief Valve Start-to-Discharge Pressure (375 psig)
• Customer Information Labels
• Proper Valve Protection (neck ring or cap)
• Proper Foot Ring Attachment
• Check for the OPD valve (if required)
• Motor Fuel Cylinders
o Relief Valve Weather Cap
o Proper Relief Valve Discharge Orientation (away from the
industrial truck operator)
o Weather Cap on Filler Valve
o Quick-Closing Coupling on Service Valve
• Stationary Cylinders
o Relief Valve Weather Cap
o Weather Cap on Filler Valve
Purging New Cylinders of Air

Before liquid LP-Gas is introduced into new cylinders, it is necessary to purge
them of air and moisture. Some cylinder manufacturers pre-purge new cylinders
(including vacuum purging) before they are shipped. Refer to subsection 5.1.9 of
this handbook for further information on purging.
Preparing and Loading LP-Gas Cylinders on the Delivery Vehicle
When delivering LP-Gas cylinders to residential or industrial customers, the

driver is responsible for the delivery vehicle and for transporting cylinders safely
and efficiently. Cylinders and their valves and fittings must be leak-free before
being loaded onto vehicles. Various kinds of equipment are designed and used
to lift the cylinders on and off the delivery vehicle, and to secure them while being
transported. Regular inspection and maintenance of the delivery vehicle, its
equipment, and the cargo is also required.
Protecting the Cylinder Valves and Fittings
The transportation of cylinders must include protection against physical damage

to the cylinder valves and fittings while in transit.
48
Procedures
For cylinders manufactured after October 1, 2007, a cylinder must have its valves
protected by one of the following methods:
• By equipping the cylinder with securely attached metal caps of sufficient

strength to protect valves from damage during transportation; or
• By constructing the cylinder so that the valve is recessed into the cylinder
or otherwise protected (e.g., valve collars) to the extent that it will not be
subjected to impact damage when the container is dropped onto a flat
surface.
Additionally, cylinders of 45-pound LP-Gas capacity or less must have a plug,

cap or an approved quick closing coupling in place on or in the service valve
(such as the back check in valves equipped with a listed overfilling protection
device) when the cylinder is not connected for use.
Loading and Securing the Cylinder Cargo
Cylinders must be transported in a suitable rack or frame or on a flat surface, and

fastened securely in a position to minimize the possibility of movement, tipping,
or physical damage related to each other or to the supporting structure while in
transit.
Figure 5.1.6b – Vertically Secured Cylinders
49
Procedures
Figure 5.1.6c – Horizontally Secured Cylinders (Relief Valve at Top)
Before delivering cylinders to customer locations, they must be properly loaded

and secured on the vehicle.
Before loading you must…

• Inspect all cylinders for proper markings and fitness.
• Check to see that cylinder valves and fittings are leak free before loading.
• Protect cylinder valves and fittings against physical damage.
During loading…
• Place cylinders so that the weight remains evenly distributed on the
service bed. An ideal load places most of the weight on the front and rear
axles, and evenly distributes it, both side-to-side and front to back. An
unbalanced load is very dangerous, and can make the vehicle hard to
handle or even overturn.
• Load cylinders in a suitable rack or frame on the service bed.
• Securely restrain cylinders in an upright, vertical position to keep them
from shifting, falling, or being ejected from the truck.
• Position cylinders so that their relief valves are in direct communication
with the vapor space at all times. Secure them in this position with binders
or straps
Checking the Cylinder Delivery Vehicle for Placarding
The vehicle must be properly placarded before leaving the bulk plant. DOT
regulations require any vehicle transporting more than 1,000 pounds of LP-Gas,
including the weight of the cylinders, to be placarded on the front, rear, and on
both sides. Placards must indicate the hazard class name and hazard class
50
Procedures
number. For LP-Gas (propane), these are:
• FLAMMABLE GAS (indicated by red color and flame symbol),

• Hazard Class or Division - 2 or 2.1,
Alternatively, the hazardous material identification number (“1075” for LP-gas

and “1978” for propane) may be shown in place of “flammable gas” on the
placard. Examples are shown below.
Verifying Shipping Papers and Emergency Instructions
If permanent shipping papers are used, the date and number of cylinders loaded
at the beginning of the delivery route must be recorded on the permanent
shipping paper, typically with a wax pencil marker (see Figure 5.1.6d on next
page).
If single-trip shipping papers are used, they should be completed according to

company procedures.
Shipping Papers
DOT requires that shipping papers accompany each shipment of propane

transported in commerce. They should be available for authorities in the event of an
accident or an inspection. When driving, the shipping papers must be within
immediate reach when a lap safety belt is in place, or in a holder mounted on the
inside of your door. If you leave the vehicle, place these documents in the door
holder or where they can be seen on the driver’s seat.
Shipping papers must contain the hazard identification information as it
applies to bobtails and cylinder delivery vehicles including:
Proper shipping name
UN identification number/proper shipping number
Hazard class division
NON CORROSIVE
Maximum quantity of LP-gas
sequence of information provided on shipping papers has been changed by the DOT. The industry
will have until January 1, 2013 to comply with the new format.
51
Procedures
If permanent shipping papers are used for cylinder delivery vehicles, the date and number of
cylinders loaded at the beginning of the delivery route must be recorded (typically with a wax pencil
marker). If single-trip shipping papers are used, they should be completed according to company
procedures.
52
Procedures
53
Procedures
EMERGENCY RESPONSE INFORMATION
You must carry emergency response information along with the hazmat shipping
papers in your CMV. You must keep this information readily available for emergency
responders, enforcement authorities, and company personnel, in the event of an
incident.
The emergency response information must also be available at LP-gas transfer and
storage facilities in case of emergency.
Each state may have different requirements. Be sure to follow your company’s policy
and state requirements, as well as DOT regulations.
At a minimum, the emergency response information must include the
following:
Description of the hazardous material.
Immediate precautions to take in the event of an incident.
Risks of fire or explosion and immediate methods for handling small and
large fires.
Initial methods for handling spills or leaks in the absence of fire.
Immediate hazards to health and preliminary first aid measures.
Emergency response telephone numbers.
This information must be either on the shipping papers or kept with the shipping
papers.
54
Procedures
5.1.7 Preparation and Transportation of ASME Containers
5.1.7.1 Tank Inspection and Preparation at Bulk Plant
The following items (as a minimum) should be checked on each tank transported
from the bulk plant to a customer location:
• Check for leaks at all tank welds and fittings.
There are at least 19 welds on a typical ASME tank used for LP-Gas storage.
In addition, threaded fittings installed in the tank represent at least 11
additional places where leaks could occur. Each of these welds and
threaded connections should be checked for leakage with the tank
pressurized, using a suitable leak detection solution or leak detection device.
• Verify that any tank over 125 gallons water capacity contains 5% or less LP-
Gas in liquid form.
If more than 5% liquid is present in a tank larger than 125 water gallons
capacity, the excess liquid must be evacuated before the tank can be
transported on public roadways.
Figure 5.1.7b - Liquid Level < 5%
• Check the condition of the tank coating to be sure that it is proper for the tank
installation, whether it is for underground or aboveground service.
The protective coatings used on both types of tank installations are important
to maintaining structural integrity and protecting the container from loss of
wall thickness due to corrosion. The coating for underground tanks is an
integral part of the tank’s corrosion protection system. If the protective
coating of a tank is damaged, the tank coating should be repaired or another
tank selected for installation. Coating touch-up materials should be
55
Procedures
transported with the tank to make any needed final repairs to tank coatings at
the installation site.
• Check the condition of each tank valve and fitting.
Check to see that weather caps are in place on filler valves, relief valves, and
the vapor equalizing valve. Verify that the metal plug is in place and sealed on
the liquid withdrawal valve. If the tank is a new tank and not vacuum-sealed by
the manufacturer, be sure that the container is properly purged of air before it
is transported to the customer location. Older tanks that have been open to
the atmosphere must be purged as well (see subsection 5.1.9 of this
handbook).
Relief Valve Filler Valve
Vapor Equalizing Valve Liquid Withdrawal Valve
Figure 5.1.7c – Proper Installation of Weather Caps
• Verify that the tank is properly marked and labeled for transportation.
ASME data plate markings or ASME certification stampings in the tank head
or shell must be legible.
56
Procedures
Figure 5.1.7d – Underground Tank Data Plate
• Check the condition of the tank’s lifting lugs and supports.
After the condition of the ASME tank has been determined to be satisfactory, the
tank and any required installation materials should be readied for loading.
Secure installation items, such as masonry foundation blocks, since they are also
considered cargo that must be secured as any other cargo transported under
DOT regulations.
5.1.7.2 Loading of ASME Containers to be Transported
Coordination of ASME tank loading and unloading is essential to avoid personnel

injury or equipment damage.
Planning and Safety Review
When two or more people are involved in any task, efficiency and safety are
dependent on planning and clear communications. Handling and setting tanks
requires a coordinated effort. Before the tank is lifted, transported, and placed in
its new location, pre-job planning that includes everyone who will be involved
should be conducted and should address the following:
• A detailed tank loading or unloading plan along with a description for each
person’s responsibilities in the operation.
• Assignments for equipment operators and the means used for

communicating and coordinating each step of the job. Details, such as who
will act as spotter for the crane operator and the meaning of hand signals or
other means of communication that will be used, should be established.
• The locations of trucks and other equipment being used to make sure that
crane lifts, swings, and other movements are completed safely.
• A “Walk-Through” at the installation site by drivers and equipment operating

personnel before trucks or cranes are brought onto the site. Special care
should be given to ensuring proper support for vehicles, avoiding buried
57
Procedures
structures and overhangs, and slopes or terrain hazards that could lead to
truck or crane overturn.
• Safe working procedures, Personal Protective Equipment and any special

tank handling requirements, with emphasis on prohibiting personnel from
beneath a tank during lifts, swings, or positioning.
Truck-Mounted Crane Operations
When LP-Gas company employees use company-owned truck-mounted cranes

to load, unload, and install tanks, they are responsible for all the phases of these
operations. OSHA regulations regarding truck crane operations are found in 29
CFR 1910.180.
Operating the Truck-Mounted Crane
Truck crane operators should read and follow the manufacturer’s

instructions for inspecting, maintaining and operating the crane.
After the pre-job planning session, the crane truck should be located on
level ground so that the ASME tank can be lifted and positioned within
safe working limits of the crane. The vehicle parking brakes should be
set, and chock blocks placed in front of and behind the vehicle’s rear
wheels. The crane outriggers should be fully extended and locked into
position. Outriggers should be adjusted to level the crane structure in
accordance with manufacturer’s operating instructions. Crane outriggers
(where provided by the manufacturer) are used to prevent damage to the
truck chassis and maintain stability.
Safety Inspections
Before lifting the tank, the crane should be inspected thoroughly. If the
tank contains more than 5% liquid, the tank’s lifting lugs or “eyes” should
not be used. Instead a “basket lift” should be made using slings or chains
with adequate load ratings.
OSHA regulations regarding slings are found in 29 CFR 1910.184. Also

OSHA publication 3072, Sling Safety, provides additional guidance.
Lifting Operations
After inspecting the sling(s), the crane operator must determine how the
tank will be lifted, how the sling(s) will be arranged, and if additional slings
or other equipment is needed for the load. The slings being used should
have load ratings well in excess of the weight of the tank and its contents.
58
Procedures
Consistently applying knowledge of crane and lifting equipment fundamentals,

performing thorough inspections, coordinating communications, conducting pre-
job planning, verifying that lifting equipment is properly maintained, and
observing all necessary precautions will help protect employees from injury while
protecting tanks, equipment, and customer property from damage.
5.1.7.3 DOT Regulations Pertaining to Transporting ASME Containers
The primary regulatory requirements for transporting ASME tanks used for LP-
Gas are found in 49 CFR 173.315(j). To highlight these requirements for
awareness purposes, ASME containers used for LP-Gas service and intended
for stationary installation on consumer premises may be shipped by private motor
carrier from a bulk plant only under the following conditions:
• Each container must be constructed in compliance with the requirements

of the ASME Code and must be marked to indicate compliance (data
plate or data specification stamping) in the manner specified by the
respective code.
• Each container must be equipped with safety devices in compliance with

the requirements as specified in NFPA 58.
• The containers must be braced or otherwise secured on the vehicle to

prevent relative motion while in transit. Valves or other fittings shall be
adequately protected against injury during transportation.
Containers can not be shipped when charged with LP-Gas to

more than 5 percent of their water capacity. The only exception is
that containers 125 gallons or less water capacity may be shipped
when charged with LP-Gas in compliance with DOT filling density.
Load Inspection Rules for Tanks and Cargo in Transit
The DOT regulatory reference for checking the security of cargo on commercial
vehicles is found in 49 CFR 392.9. These regulations prohibit a driver from
operating a commercial motor vehicle unless the cargo is properly distributed and
secured in compliance with DOT requirements. Of most importance, the driver
must:
• Inspect the cargo and the devices used to secure the cargo within the first
50 miles after beginning a trip, and make necessary adjustments; and
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Procedures
• Re-examine the cargo and devices that secure the load, making
necessary adjustments whenever:
o The driver has a change of duty status; or

o The commercial motor vehicle has been driven for 3 hours; or
o The commercial motor vehicle has been driven for 150 miles.
Requirements for Transporting ASME Containers

Propane containers larger than 120 gallon water capacity are called “bulk packagings” under
U.S. Department of Transportation regulations when they are being transported commercially.
They are generally classified as one of two types according to their design and function:
• ASME containers (or tanks), which are designed for the storage of LP-Gas, are installed
at bulk plants or customer locations in what are referred to by NFPA 58 as a “stationary”
or “permanent” installations. As mentioned previously, ASME tanks with water
capacities 125 gallons or more cannot be legally transported from a bulk plant after they
have been filled with liquid LP-Gas to more than 5% of their water capacity.
• DOT specification portable tanks and intermodal tanks are designed to be transported
while being filled to their maximum permitted filling density. These tanks have structural
protection for valves and fittings that is not provided on stationary ASME storage tanks.
Vehicles transporting bulk packaging’s that contain propane, must be placarded

on each side and each end of the vehicle in accordance with the requirements of
the U.S. Department of Transportation regulations.
Of course, DOT regulations for securing the load and protection against shifting
and falling cargo always apply, whether or not the vehicle is required to be
placarded.
The DOT has specific requirements for placarding (49 CFR Part 172.504) and
marking (49 CFR Part 172.302) bulk packages (DOT Portable Tanks and ASME
containers greater than 120 gallons). Each bulk package is required to be have
a marking and/or placard with the hazardous material identification number (1075
for LP-gas) and the hazard class (2) or hazard class division (2.1) on a red
colored diamond as follows:
• On each side and each end if the ASME container or the DOT portable
tank has a water capacity of 1,000 gallons or more
• On two opposing sides if the ASME container or the DOT portable tank
has a water capacity less than 1,000 gallons
The marking identification number can be displayed separately on an orange

panel, or it can be displayed as part of the placard. Two options are shown
below.
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Procedures
solid line
hazard inner border
0.3 in. 0.2 to 0.25 in.
high from edge
hazard class
0.25 to 0.5 in. 3.9 inches
high each side
Plus
OR
2.1
In addition to the required hazardous material identification number, portable

DOT tanks must also be marked with the following:
• The proper shipping name (either “propane” or “LP-gas”)
• The name of the tank’s owner or lessee
For either portable DOT tanks or ASME containers, if the identification number
on the portable tank or ASME container is not visible, the transport vehicle itself
must be marked with the identification number on each side and each end of the
vehicle
To comply with DOT regulations (per 49 CFR 392 & 393, Subpart I), ASME tanks
should be secured with at least 2 cargo straps and binders (or chains and
binders) having sufficient working load limit ratings for the tank(s) being
transported (see Figure 5.1.7g).
Additional cargo straps or chains should be used for each additional 10-foot
length of tanks longer than a typical 1,000 gallon ASME tank or where two
restraints do not meet minimum working load requirements for heavier loads.
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Procedures
Prop a ne in Ta nk–
120 -999 ga ls.
Minim um –
Ship p ing La b els
2 Tie -d o wns
Both Sid es; 1,000
g a ls. & Larg er Both
Sid es & Eac h End
Propane Service
DOT 654321
1075
2.1
Vehic le Pla c ards–

Front, Ba c k & Both Sid es
Figure 5.1.7g - Labeling, Placarding, and Cargo Restraints
If an ASME tank has a valve installed in a bottom opening that could be

damaged during transit, the tank should be secured on suitable cargo blocking or
timbers to provide adequate clearance between the vehicle bed and the valve.
Cargo restraints should be arranged to make sure that all valves are protected
during transit. If the dome of the tank cannot be adequately secured during
transportation, it should be removed and secured in a toolbox or other location,
but not carried unsecured in the vehicle cab.
DOT regulations prohibit the display of hazardous material placards if the vehicle
is not transporting cargo containing hazardous materials. Therefore, vehicle
placards must be removed or covered during the return trip after ASME tanks are
delivered.
5.1.8 Evacuation of Containers
A full understanding of the operation of the liquid evacuation process is essential

in order to safely remove the liquid propane from containers and reduce the
potential for safety incidents associated with the following hazards:
• Exposure to liquid propane can result in freezing of the skin.
• Exposure to flammable gas and other materials at high pressure.
• Potential ignition of flammable gas.
The area around the evacuation operations must be maintained free of any
ignition sources. For example, operating internal combustion engines should be
at least 15 feet away from the point of transfer. Additionally, smoking, open
flame, portable electric tools and extension lights should not be permitted within
25 feet of the transfer point.
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Procedures
5.1.8.1 DOT Cylinders
Evacuation by Differential Pressure

(formally known as Gravity Transfer)
Propane liquid can be removed from portable and exchange DOT

cylinders by differential pressure. Larger cylinders, especially exchange
cylinders that do not have neck rings to protect the service valve, should
be secured in a cylinder inverter.
To transfer the liquid out of the cylinder:
• Invert the cylinder in an elevated position above a receiving

container approved for storage of LP-Gas.
• Connect the two containers with a high-pressure LP-Gas hose
assembly.
• Open the service valve on the container to be evacuated and the
fill valve on the receiving container to allow the liquid to drain into
the receiving container (see Figure 5.1.8a).
Cylind e r Inve rte r with

Se c uring Stra p s
Hig h Pre ssure LP-Ga s
Ho se with Exc e ss Flo w &
Shuto ff Va lve Ea c h End
Re c e iving
ASME Ta nk Eleva ted Doc k or Pla tform
Figure 5.1.8a - Evacuation by Differential pressure
When evacuating liquid from stationary DOT cylinders, inverters must be

rated for the load of the cylinder and the product within it.
Evacuation Using a Compressor
Bulk plant operators frequently use a compressor system for evacuating

cylinders. One of the most common methods used is the scavenging
system, which consist of a small scavenging tank, a stationary or portable
compressor, and the bulk plant storage tank. See Figure 5.1.8b for a
typical scavenging system.
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Procedures
When this system is used to evacuate a container, the following process

is typically used:
• The vapor lines that connect the compressor to the two tanks are
opened and the liquid line is closed.
• When the compressor is turned on, it pulls vapor out of the

scavenging tank into the bulk storage tank.
• As a result, the pressure in the scavenging tank is reduced.
• This creates a difference in pressure between the scavenging tank

and the cylinder being evacuated, causing the liquid in the cylinder
to flow to the scavenging tank.
• When the scavenging tank is at the maximum permitted filling

level, the compressor is turned off and all valves are closed.
• The vapor lines connecting the bulk tank and scavenging tank to
the compressor are reversed.
• When the compressor is started again, the compressor pulls vapor
from the bulk tank and forces it into the scavenging tank.
• The higher pressure now in the scavenging tank forces the liquid
in the scavenger tank into the plant storage tank, emptying the
scavenger tank so it can be used again to evacuate other
containers.
Cylinders designed for liquid service (liquid service valve with dip tube)
are very easily emptied using a scavenger tank. The following is a typical
procedure:
• A LP-Gas liquid hose, with a shutoff valve on each end, is
connected between the cylinder and the scavenger tank.
• When the compressor is turned on, the higher pressure in the
cylinder will force liquid to flow up the dip tube in the cylinder and
into the scavenger tank.
• When the liquid level in the cylinder reaches the bottom of the dip
tube, liquid can no longer be removed.
If the cylinder must be totally evacuated, the remaining contents must be
flared or carefully vented.
Cylinders designed for vapor service are not as easy to evacuate. Since
a vapor service valve does not utilize a dip tube, the cylinder must be
64
Procedures
inverted (i.e., bottom side up) so liquid can be withdrawn through the
vapor service valve (see Figure 5.1.8b).
Figure 5.1.8b - Evacuating Vapor Service Cylinders
An inversion rack, also called an evacuation rack, is used to support the

cylinder (see Figure 5.1.8c). Once inverted, a liquid transfer hose is
connected between the service valve on the cylinder and the scavenger
tank, creating liquid flow to the tank.
Figure 5.1.8c – Cylinder Inverter
If the cylinder is evacuated of liquid propane for the purpose of

comparing its weight to the manufacturer’s stamped tare weight as
part of requalification, draining the liquid is all that is required. It can
remain pressurized with vapor for the purposes of tare weight comparison
and requalification.
If the cylinder must be de-pressurized in preparation for valve or fitting

replacement, the vapor must be reduced to near atmospheric pressure
which might require the flaring of vapor.
65
Procedures
Conducting Vapor Flaring Operations
Flaring is the process of burning LP-gas removed from storage containers

in a controlled and safe manner. Although venting may be the simplest
way to evacuate a container, it is not the safest means and not permitted
in some areas. Because of these restrictions, most LP-Gas marketers
evacuate tanks and cylinders by flaring or burning off most of the LP-Gas
in a burner.
Figure 5.1.8d – Propane Burning from Flare Tower
Many marketers remove most of the LP-Gas liquid by pump or

compressor, thus reducing the length of time of the flaring operation.
Once the majority of the liquid has been removed, the remaining LP-Gas
is usually flared.
The following procedure provides guidance for flaring LP-Gas from
cylinders and ASME tanks with water capacity <2,000 gallons. Check
company policies and state and local codes for any additional
requirements on flaring the container. Training information and
instructional details associated with flaring operations are provided in
CETP Module 2.4.4.
In certain areas, local fire codes or company policies require

you to contact the local fire department and notify them that
the container is to be flared.
1. Evacuate as much LP-Gas from the container as possible.
2. Select the proper site for flaring the LP-Gas. If a designated area
for flaring does not exist, select a site with your supervisor that
meets the company and code requirements.
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Procedures
3. Select the necessary equipment for flaring the remaining LP-Gas

in the container. Again, if equipment has not been designated for
flaring operations, check with your supervisor to select and
assemble the equipment.
4. Lay out and assemble the flaring equipment, including all the
necessary hoses, fittings, supports and burner to flare the
remaining LP-Gas in the container.
5. Before opening the container and burner assembly valves and

prior to igniting the burner, pressure test the flaring assembly. Do
not ignite the flaring burner until you are sure that the supply is
gastight.
6. Flare the remaining LP-Gas in the container.
• Place the fire extinguisher next to the burner support.
• Inform your supervisor, as well as the other employees at the

location, that the container is about to be flared.
• Following manufacturer's instructions, ignite the burner.
If an accidental fire develops during the flaring

operation, immediately close all shutoff valves
(including the container service valve) to
extinguish the fire.
7. Observe the pressure gauge on the service valve or purging

adaptor. When the pressure drops below 15 psig, temporarily
shut down the burner and allow the pressures in the tank or
cylinder to increase.
Because of the high demand of the burner,

the container may refrigerate during the
flaring operation. If a frost line develops on
the cylinder, temporarily shut down the
burner and allow the pressure in the
container to increase.
8. When the vapor pressure no longer increases (above 15 psig),

flare the remaining vapor until the burner extinguishes.
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Procedures
9. While wearing appropriate PPE, bleed down and disconnect the

flaring equipment. If applicable, disassemble and store the
equipment.
Flaring operations should never be left
unattended. Qualified personnel should
continuously monitor flaring equipment and
conditions. If qualified personnel must
leave the flaring operation for any reason,
the operation should be shut down and the
valve(s) on the container being flared
should be closed.
5.1.8.2 ASME Containers
Normally, LP-Gas is evacuated from ASME containers at the customers’

locations. However, there are various circumstances where an ASME
container must be evacuated in the bulk plant.
When transferring LP-Gas from a stationary ASME LP-Gas storage

container to a CTMV cargo tank, the following safety precautions can
serve as a guideline:
• All hoses used in the evacuation procedure must be

designed, listed and marked for use with liquid propane (1750
psig bursting pressure, and 350 psig working pressure).
• All sources of ignition must be controlled as noted in Section

4 of this handbook.
• At least one recently inspected fire extinguisher, having a

minimum capacity of 18-lb. dry chemical with a B:C rating,
must be within easy reach during the entire operation.
• A qualified individual must be present at the operation during

the entire evacuation procedure.
• Proper PPE should be worn per company policy.
Equipment for Evacuating the ASME Container
CTMV Pump or Portable Compressor

If a CTMV pump is used, the liquid transfer hose must be as short
as possible, but no longer than 50 feet. If the CTMV cannot be
positioned any closer than 50 feet, a small portable compressor
should be used.
68
Procedures
Because of the limited capacity of the transfer and

withdrawal valves, the vehicle pump can "starve" for
liquid propane and become damaged.
If a portable compressor is not available, consider moving the

ASME tank to a different location on the site, closer to the CTMV.
When an ASME tank containing more than 5% liquid is lifted, the

tank’s lifting lugs should not be used. Instead, suitable lifting
slings that have sufficient weight-bearing capacity ratings should
be used to lift the tank.
Liquid Transfer Hose
The liquid transfer hose connected between the two tanks should
have the following features (see Figure 5.1.8e):
Figure 5.1.8e - Liquid Transfer Hose
• It should be listed and approved for liquid propane gas

service (350 psig operating pressure, 1750 psig burst
pressure).
• The length should be as short as possible and at least 3/4"

(preferably 1") in diameter.
• Manual shutoff valves such as snap-action globe valves,

hand wheel-operated globe valves, or ball valves should
be installed on both ends of the hose.
• A hydrostatic relief valve should be installed in the liquid

assembly to prevent the hose from rupturing if liquid
propane is trapped between the two shut-off valves.
• Fittings must be selected that will connect the liquid supply

line to the two tanks.
69
Procedures
• All threaded connections in the liquid line, except POL and

ACME threads, should be sealed with thread sealing
compound.
Vapor Hoses
If a CTMV pump is used, a vapor equalizing hose must be

connected between the stationary ASME tank and the cargo tank,
balancing the vapor pressure between the two. During the
evacuation, occasionally check for vapor flow to make sure that
the ASME tank’s excess flow feature in the vapor equalizing valve
does not slug.
If a compressor is used, two vapor hoses are needed. Attach

one to the bulk truck (suction line) and the other to the stationary
ASME tank (discharge line). Follow the instructions of the
compressor manufacturer and your supervisor to locate or
assemble vapor lines.
Adapters
If the ASME container being evacuated is not equipped with a

vapor equalizing valve, a purging adapter must be installed in the
vapor service valve outlet (see example in Figure 5.1.8f).
Figure 5.1.8f - Purging Adapter

(POL to Male ACME)
Liquid propane in an ASME container can be removed either

through a top or bottom opening. ASME containers built prior to
1961 can be evacuated through the filler valve in the top of the
tank since they have dip tubes installed which extend to the
bottom of the tank to evacuate liquid through the filler valve.
However, a special unloading adapter is needed to operate the
filler valve. When the adapter is installed on a filler valve, the
70
Procedures
moving operator stem pushes open the back checks in the filler
valve so the liquid can be removed from the container.
There are several types of unloading adapters available each with

its own operating procedure. Read the manufacturer's instructions
that accompany the adapter used.
Anyone using an unloading adapter to evacuate a

container through a filler valve must have a thorough
working knowledge of the liquid withdrawal adapter and its
effect on the double back check feature of the filler valve.
These adapters are not intended to be, nor should they be
used as, a permanent means of dispensing liquid for any
purpose.
Actuated Liquid Withdrawal Excess Flow Valves
All tanks built after 1963 are spray-filled and should be equipped
with a separate actuated liquid withdrawal excess flow valve to
evacuate liquid from the tank (Figure 5.1.8g). As long as the valve
remains closed, it acts as a back check and prevents any gas
from escaping into the atmosphere. Once the valve is opened,
the valve disc can move up and down freely on the operator stem,
automatically changing it to an excess overflow valve.
Figure 5.1.8g
Actuated Liquid Withdrawal Excess Flow (Evacuation) Valve
These withdrawal valves may be installed in the bottom, top, or

side depending on the internal construction of the tank.
71
Procedures
In some cases, a damaged seat could allow an excessive

amount of liquid to be discharged when the closing cap is
loosened. If a significant amount of liquid continues to be
blown from under the closing cap for more than 30
seconds, it is unlikely that the internal seat will prevent a
dangerous amount of gas from escaping. If in doubt, do
not remove the closing cap..
A transfer valve with a machined adapter (Figure 5.1.8h) must be

used to evacuate a tank through a liquid evacuation valve. When
the transfer valve and adapter are screwed into the evacuation
valve, the machined adapter forces the operator shaft down and
moves the valve disc off of its seat.
Install a transfer valve with a 3/4" NPT inlet and a 1 3/4" ACME
hose connector in the outlet. Use the machined adapter supplied
by the evacuation valve manufacturer.
Figure 5.1.8h - Transfer Valve with Machined Adapter
Read and strictly follow manufacturer instructions for the

installation, use and removal of evacuation transfer valves.
Observe all warnings and precautions. If you do not have
experience evacuating containers, ask your supervisor for
assistance.
Procedure for Evacuating the ASME Container
The following procedures for evacuating LP-Gas from a stationary ASME

tank are designed as a guide when using a CTMV or portable
compressor. These procedures are based on common industry practice
72
Procedures
and provisions in NFPA 58. Check your company procedures and state
and local codes for any other requirements that apply.
Information outlining features of liquid withdrawal valves, unloading

adapters and their installation methods is provided in the Supplemental
Information Section of CETP Module 3.1.5. Always read and follow
manufacturers’ instructions for use. Use the adapters specified by
manufacturers and wear personal protective equipment while evacuating
LP-Gas containers.
On most LP-gas containers larger than 125 water gallon capacity and
manufactured prior to July 1, 1961, a liquid withdrawal (evacuation)
internal dip tube was attached to the bottom of the filler valve by the
manufacturer and extended to the bottom of the container. Since 1961,
container manufacturers have installed a separate valve, called an
actuated liquid withdrawal excess flow valve, for liquid evacuation of
domestic containers.
LP-Gas should never be vented into the atmosphere

through these valves except as required during installation
and removal of the transfer valve.
The LP-Gas evacuated from stationary containers is normally transferred

into the bulk delivery vehicle cargo tank. In some cases, an empty LP-
Gas storage container of the same capacity is used when a tank change
out is done.
The evacuation process may use either a pump or compressor to transfer

LP-Gas liquid from one tank to another. Some CTMVs are equipped with
an external inlet to the pump called the auxiliary inlet, which may be used
for evacuation.
Regardless of the equipment used, since evacuation requires the transfer

of both LP-Gas liquid and vapor, all procedures and safety precautions
should be fully understood and applied. The procedures described below
are limited to the following tanks, equipment and conditions:
• Stationary ASME tanks with water capacities between 125

gallons and 1,000 gallons.
• Liquid being withdrawn through a liquid withdrawal valve with a

transfer valve installed.
• The tank being used to receive the liquid from the stationary
tank being evacuated is a bulk delivery vehicle cargo tank.
73
Procedures
• A portable propane compressor or the bulk delivery vehicle

pump is being used to evacuate the liquid in the stationary
tank.
1. Determine the quantity of LP-Gas to be transferred. Check to see that

the liquid level in the cargo tank is low enough to handle the amount
of LP-Gas to be evacuated from the ASME tank without overfilling the
cargo tank.
2. Position the bulk delivery vehicle to receive LP-Gas.
• Position the compressor between the delivery vehicle and the

stationary tank being evacuated.
Figure 5.1.8i
Evacuating ASME Tank Using a Portable Compressor
• The delivery vehicle should be approximately 10 feet from the

suction side of the compressor. The maximum distance
between the compressor and the two tanks will depend on the
length of the vapor hose.
3. Connect a transfer valve to the outlet of the withdrawal valve on the

stationary tank.
• Screw a machined unloading adapter into the inlet of the

transfer valve.
When loosening the plug or cap from the liquid

withdrawal valve, be sure only the plug is loosened and
removed. If an excessive volume of LP-Gas leaks from
the valve, reinstall the plug and follow manufacturer’s
instructions.
• Install the transfer valve according to manufacturer’s

instructions.
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Procedures
• Once installed, close the transfer valve.
4. Close all valves in the liquid transfer line.
5. Lay out the liquid transfer hose between the stationary tank and the
cargo tank.
6. Connect one end of the liquid transfer hose to the outlet of the transfer
valve and the other end to the fill connection located on the cargo tank
of the delivery vehicle.
7. Connect the vapor hoses between the compressor and tanks.

Connect the discharge hose between the discharge side of the
compressor and the vapor equalizing valve (or purging adapter) on
the stationary tank.
• Connect the suction hose between the suction side of the

compressor and the equalizing connection on the cargo tank
of the delivery vehicle (see Figure 5.1.8i).
8. Pressure test the vapor and liquid hoses.
• Slowly open one valve at a time, starting with the transfer

valve in the stationary tank, to pressure test the liquid supply
line.
• Check all connections downstream to the next closed valve for

leakage once a valve is opened.
• Slowly open each valve downstream one at a time after each

section of line is considered tight.
• Close all valves in the line and make repairs if any leaks are
detected.
9. Transfer as much liquid as possible from the stationary ASME LP-Gas

tank to the cargo tank. Follow the compressor manufacturer
instructions. Typically, portable compressors are run only for short
time periods of one or two minutes to create a pressure differential
between the two tanks.
10. Bleed down and disconnect all hoses.
• Bleed down and disconnect the fitting of the liquid transfer

hose connected to the closed transfer valve.
75
Procedures
• Bleed down and disconnect the liquid transfer hose connection

at the bulk LP-Gas delivery vehicle pump-off adapter or fill
connection.
• Fully open the transfer valve and allow LP-Gas to flow through
until the excess-flow check valve "slugs" shut.
If the excess flow valve does not “slug shut, immediately

close the transfer valve. Do not remove the transfer
valve until the pressure in the tank has been reduced to
0 psig.
11. Once the pressure has been reduced, the withdrawal valve must be
serviced before the ASME tank is returned to service.
5.1.9 Purging of Containers
The following procedures apply to new containers designed and used for storing
LP-Gas (propane) at capacities up to and including 2,000 gallons water capacity,
including both ASME and DOT containers. Only personnel who have been
properly trained and qualified in the procedures related to container vapor
purging and methanol injection should perform the tasks outlined in this section.
All personnel handling LP-Gas and methanol should read and

understand the Material Safety Data Sheets (MSDS) for each
material prior to handling. Personal Protective Equipment should
be used per the MSDS.
Purpose
Because air, moisture and other contaminants might be present in new

containers (or in some circumstances used containers), it is essential that these
be removed before filling a container and placing it into service. Purging a
container with LP-Gas is required because air and moisture can cause corrosion
(commonly called “rusting”) to occur on the inside surface of the container.
When that occurs, the effectiveness of the ethyl mercaptan odorant in the LP-
Gas can be significantly reduced and result in “odorant fade”, a hazardous
situation. Because methanol attaches itself to water molecules and keeps
moisture (water) from freezing when the LP-Gas vaporizes, methanol may need
to be added to storage containers to act as a drying agent.
76
Procedures
Purging LP-Gas Containers with LP-Gas (Propane) Vapor
ASME tanks and DOT cylinders are usually purged of air at the bulk plant using
LP-Gas vapor regulated to 15 psig. Note that purging may sometimes be done
through an electrically grounded purging stack (see Figure 5.1.9a).
Figure 5.1.9a – Container Purging Stack
To purge a container:
1. Open the service valve to bleed any air from the tank.
2. Attach the vapor hose end valve to the service valve with the
appropriate adapter.
3. Pressurize the container with LP-Gas vapor to 15 psig.
4. Close the valve on the vapor hose and bleed off the vapor using the
adapter on the filler valve.
5. Repeat this process 5 times.
A final vapor charge of 15 psig should be retained in the container before filling
with liquid LP-Gas.
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Procedures
Moisture Removal Using Methanol Injection
Vacuum Purged Containers
Some marketers pre-treat new ASME tanks for moisture by adding a

small quantity of methanol. Recently, some tank manufacturers have
made this process easier by evacuating air from new tanks and then
sealing the tank valves with a vacuum inside (Figure 5.1.9b).
Figure 5.1.9b – New Vacuum Purged Container
The negative pressure (less than atmospheric pressure) shown on the

gauge in the above photograph indicates that the tank is leak-free and
that methanol can be introduced into the tank by suction.
In order to avoid air entering the tank during the methanol transfer, the
hose in the methanol container must extend to the bottom of the container
and the service valve on the tank should be closed before the methanol
level gets to the level of the hose opening.
After the methanol is transferred into the tank, the tank is pressurized with
LP-Gas vapor (see Figure 5.1.9c). All valves should be closed after the
tank is pressurized. The manufacturer’s applied shrink-wrap plastic
should then be removed from the tank valves to indicate that the tank is
pressurized with LP-Gas.
78
Procedures
Figure 5.1.9c - Pressurizing New Vacuum Purged ASME

Tank with Propane Vapor
79
Procedures
Injecting Methanol into Pressurized Containers
Methanol can be injected into containers by using a short length of LP-

Gas hose with a female ACME connector installed on the container filler
valve, while a male ACME connector on the other end is secured to the
bulk truck delivery hose end valve adapter. LP-Gas in the delivery hose
forces the methanol into the container when the hose end valve is opened
The procedure is as follows:
1. Inspect the short hose that will be used to inject the methanol and be
sure it is free of defects that would require it to be removed from
service.
2. Pull the CTMV (bobtail/transport) delivery hose end to the receiving

tank and place it within arms reach of the filler valve.
3. Attach the female ACME adapter of the short hose to the filler valve of
the receiving container and tighten to seal the connection.
4. Fill the short hose section with methanol, holding the hose end up and
being careful not to spill or splash the methanol.
5. Attach the male ACME adapter to the delivery hose end valve adapter
and seal it to make sure methanol and LP-Gas will not leak out under
pressure when the delivery hose end valve is opened.
6. Slowly open the delivery hose end valve. If there is not sufficient LP-
Gas pressure in the hose to open the receiving container filler valve,
use the CTMV pump to transfer a few gallons of LP-Gas into the
receiving container.
7. Close the hose end valve and partially loosen the short hose section
from the container filler valve, allowing the LP-Gas to vent until and
the hose is de-pressurized.
8. Remove the short hose section from the filler valve and the delivery
hose end valve.
9. Inspect the short hose section and the portion of the delivery hose
deployed for the transfer.
10. Properly stow and secure the hoses and the methanol container.
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Procedures
5.1.10 Dispensing LP-Gas
While the dispensing equipment at a LP-Gas bulk plant will vary in size and
design (e.g., storage capacity, integrated with the bulk storage tank versus stand-
alone, manual versus automatic shut-off devices), the basic procedures to follow
are typically the same. Prior to any operation, one should review and be familiar
with the dispensing equipment, piping functions, and company operating
procedures. Detailed information is provided in CETP Module 3.3 and in PERC’s
Dispensing Propane [Safely] training materials.
The following procedures apply to filling DOT cylinders and vehicle mounted
ASME containers. Only personnel who have been properly trained and qualified
in the procedures related to dispensing LP-Gas should perform the tasks outlined
in this section. All personnel handling LP-Gas should read and understand the
Safety Data Sheets (SDS) for each material prior to handling.
Filling DOT Cylinders
Operating a dispenser to fill DOT cylinders with LP-Gas requires the operator to
know the regulations that apply and the characteristics of manual or automatic
filling equipment.
Regulatory and Code Requirements for Cylinder Filling
Three of the most critical US DOT regulatory requirements related to

cylinder filling are as follows:
• Before filling each cylinder, the person filling the cylinder must
visually inspect the outside of the cylinder.
• The weight of LP-Gas filled into the cylinder must be checked,

after disconnecting the cylinder from the filling line, by the use
of an accurate scale
• No cylinder may be filled and offered for transportation in

commerce unless that cylinder has been requalified and
marked in accordance with DOT requirements. A cylinder
passing requalification by the external visual inspection must
be marked in accordance with DOT requirements.
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Procedures
Additionally, NFPA 58 requires that cylinders must be continued in

service and transported in compliance with DOT regulations, and that any
cylinder that is due for requalification must not be refilled until it is
requalified using requalification methods prescribed in the DOT
regulations. Some state jurisdictional authorities have not adopted the
2001 edition of NFPA 58 (where this requirement was first adopted), while
others may have adopted the Code with exceptions or modifications to
this requirement. If you are not sure of state or local jurisdictional
requirements for requalification of cylinders not transported in commerce,
ask your supervisor to clarify what your company’s procedures and
policies require.
NFPA 58 allows cylinders of less than 200 pounds water capacity that are
not subject to DOT jurisdiction to be filled by the volumetric method.
Operating a Dispenser
Startup
1. Inspect all dispenser equipment prior to LP-Gas transfer to

make sure that the equipment and supplies needed are in safe
and proper working order.
2. Conduct pre-fill inspections on the DOT cylinders, as described in

Section 5.1.6 of this handbook. Further details are provided in
CETP Module 3.3.3.
Please keep in mind that Overfilling Prevention Devices (OPDs)

are required by NFPA 58 (starting with the 1998 Edition) for
vertical cylinders with 4 lb - 40 lb LP-Gas capacity. In jurisdictions
that have adopted this or more recent editions of NFPA 58 without
modification or exceptions to the OPD requirements, these
cylinders must be equipped with OPDs before they are refilled.
OPDs are not required for cylinders used for industrial welding gas
service, for motor fuel service, or for horizontally mounted
cylinders manufactured prior to October 1998 and which cannot
accommodate an OPD. Horizontal cylinders must be identified by
a label indicating that they do not have an OPD installed.
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Procedures
Figure 5.1.10a – Identifying Characteristics of an OPD
OPDs are intended to be a secondary means

to protect against overfilling of cylinders. The
primary method to prevent overfilling is filling by
weight on a scale or using the fixed maximum
liquid level gauge.
If you install an OPD as a retrofit to an existing cylinder, be certain it

has the correct length dip tube for the fixed maximum liquid level
gauge. and is the correct OPD for the cylinder that is being
requalified.
1. Prior to filling any cylinder, make sure that ignition sources

are controlled, as described in Section 4 of this handbook.
2. To make sure the cylinder is properly filled, the scales

must be "zeroed" periodically.
Operation
Manual shutdown dispensers rely on the operator to determine

when the maximum permitted filling limit for a cylinder is reached
and to stop the flow of liquid into the cylinder by manually closing
one or more valves. The operator must be in attendance to
closely observe the platform scale balance beam, close the hose
end valve immediately after the balance beam rises, and then shut
down the liquid transfer pump.
Automatic shutdown dispensers follow the operating procedures

outlined in the previous section covering hydraulic, electric, and
pneumatic systems. Be sure to perform each required step listed
for manual dispensers that applies, and comply with the
83
Procedures
manufacturer’s operating instructions. Typically where multiple

filling stations are operated, the pump by-pass circuit is designed
to allow high capacity bypassing so that the pump is not shut
down until all cylinders are filled.
Regardless of whether the dispensing equipment is manually

operated or if it uses automatic shutdown systems, the operator
must set the platform scale for the proper filling weight.
1. Place the cylinder to be filled on the platform scale and set the
balance beam scale to the proper filling weight of the cylinder.
2. Determine and set the proper filling weight by adding:
Marked Cylinder Tare Weight

+ Marked Cylinder Water Capacity x 0.42
+ Weight of dispenser hose, end valve, &
adapters
Total = Scale Filling Weight Setting
3. Open the liquid outlet valve on the storage/supply tank and

any valves in the by-pass return line.
4. Connect the dispensing hose to the cylinder fill valve. Verify

that the proper hose-end valve adapter has been installed
5. Open the service valve on the cylinder as applicable.
6. Start the pump.
7. Slowly open the hose end valve.
8. Close the hose end valve as soon as the scale beam or

indicator tips.
9. Close the cylinder valve.
10. Shut off the pump.
11. Disconnect the dispensing hose.
12. Check the weight of filled cylinder after filling connector has
been disconnected. If overfilled, bleed off excess LP-Gas in a
safe location.
13. Check the cylinder valves, especially the relief valve for leaks.
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Procedures
14. Valve outlets on cylinders of 45 lb LP-Gas capacity or less

must be either plugged or equipped with a quick closing or
quick connect coupling. Plugs are not required and should not
be used for OPDs; however, it is recommended to use a dust
cap to prevent any debris from entering the valve.
15. If required, apply DOT shipping label or cylinder warning label.
[Note: Cylinders that are less than 200 lb water capacity and
not subject to DOT jurisdiction, such as non-commercial
customers transporting their own cylinders, can be filled
volumetrically. Refer to you company’s policy and check with
your supervisor before filling a cylinder by the volumetric
method.]
Shut-down
1. After the cylinder filling operation is completed, or at any time

the dispensing station is unattended, shut off the pump and
close the valves at the storage tank.
2. Disconnect and store the hose(s) on a rack inside a fence-

protected area, inside a dispenser cabinet, or secured to a
supporting structure inside the filling room. At locations that
are not weather protected, install a dust cap or plug in the
hose-filling adapter.
3. Secure the installation against tampering.
Filling Vehicle-Mounted ASME Tanks
Motor and mobile fuel tanks have several features in common:

 Data plate and/or cylinder markings
 Fixed maximum liquid level gauge
 Float gauge
 Liquid service valve
 Relief valve
 1¾" ACME filler valve
 Stop-fill/auto-stop valves—Most ASME vehicle-mounted tanks are equipped

with a stop-fill/auto-stop valve which is a combination filler valve and overfilling
prevention device.
 Valve and fitting enclosures—If ASME vehicle-mounted tanks are located
within the vehicle, such as in a car trunk or inside a pickup camper shell, the
valves must be contained within a vapor-tight enclosure. The relief valve, filler
valve, and fixed maximum liquid level gauge are fitted with pipe-away fittings
85
Procedures
to the outside of the vehicle so that all propane vapor is discharged into the
atmosphere.
Before filling ASME motor and mobile fuel tanks:

 Be sure no one is inside the vehicle.
 Make sure the vehicle ignition is turned off.
 Inspect the tank to be sure it has all the correct markings, is in good condition, and is
safe for filling.
 Restrict customers from the immediate area around the liquid propane transfer
operation.
 Make sure there are no ignition sources or combustible materials within 25 ft of the filling
connection, or metal working operations (including grinding, oxygen-fuel gas cutting,
brazing, soldering, or welding) within 35 ft.
NOTE: If filling a motor fuel tank on an RV, be sure to turn off all appliance pilot lights and
electronic ignition systems.
Engine Fuel Container Markings
A propane label is required on over-the-road general purpose vehicles powered by LP-Gas.

This label alerts emergency response personnel that propane containers are present on the
vehicle.
The label is required to be located on an exterior vertical surface on the lower right rear of the
vehicle (such as the trunk lid), but not on the bumper.
White Letter with

Black Background with
White Border
Propane Diamond Decal
Step-by-Step: Filling Vehicle Mounted ASME Tanks.
1. Follow these steps to fill mobile and motor fuel tanks correctly.
Customers are restricted from the immediate area around the
liquid propane transfer operation. Make sure there are no
internal combustion engines operating within 15 of the point of
transfer, ignition sources within 25 feet of the point of transfer,
or metal working operations (including grinding, oxygen-fuel
86
Procedures
gas cutting, brazing, soldering, or welding) within 35 feet of the

transfer point. Set the LP-Gas meter to zero.
2. Connect the motor fuel hose to the tank fill valve.
3. Open the vent valve on the fixed maximum liquid level gauge
and check for flow. If vapor appears, continue the filling
process. If liquid appears, stop the filling process because the
tank is full.
4. Start the pump and slowly open the valve on the hose.
5. When a steady white mist or fog is first emitted from the fixed
maximum liquid level gauge vent valve, this indicates the
maximum permissible fill has been reached.
6. Close the fixed maximum liquid level gauge.
7. Shut off the pump.
8. Slowly loosen the filler adapter to vent liquid LP-Gas trapped

between the filler adapter and the motor fuel tank filler valve.
Wait until LP-Gas stops venting and pressure is relieved
between the adapter and the filler valve, before completely
disconnecting the adapter.
9. Check the valve for leaks and replace the dust cap.
10. For mobile ASME fuel tanks, inform the operator that the
service valve will need to be returned to the fully open position
and appliance pilots re-lit after the vehicle has been moved
from the LP-Gas transfer area. If it is not your company’s
policy to light customer pilot lights, advise the customer to
have a professional service company or gas distributor light
the pilot lights, that if the customer does this without
professional help he/she must carefully follow the
manufacturer’s instructions.
Shutdown
When the dispenser is not in use, or at any time that a qualified

dispenser operator is not in attendance, the dispenser should be
shut down and secured in keeping with company operating
procedures. The shut down procedure should make sure that
dispenser operating valves are closed, transfer hoses are secured
in storage cabinets or their designated locations, and the
dispenser cabinet or fence gates are closed and locked.
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Procedures
5.2 Vapor Distribution Systems
The following sections contain guidelines for operating procedures specific to industrial
plants using a vapor distribution system. These facilities will have some operating
procedures that are similar to those at a bulk storage facility. Therefore, refer to the
appropriate subsections under Section 5.1 that apply to the normal operations of a large
volume vapor distribution system.
Vapor Distribution Systems – Tank Vaporization Only
While the equipment at a large volume customer operating off of a vapor distribution
system will vary in size (i.e., storage capacity, meters, regulators), the basic procedures
to follow are usually much the same as for the bulk storage tank. Prior to any operation,
one should review and be familiar with its design, layout, equipment, piping functions,
and company operating procedures. CETP Modules 4.1 & 4.2 provide detailed
supporting information.
Startup
1. Before beginning any operation make sure the transfer equipment is in

satisfactory operating condition, the bulk storage container is safe to be filled,
and the surrounding area is free from hazards.
2. The following system checks/tests should be performed during the installation

or modification of the vapor distribution system(s). Instructional details are
provided in the referenced CETP Modules:
• Purging of piping systems (per CETP Module 4.2).

• Pressure tests and inspection of piping (per CETP Module 4.2).
• Regulator operational tests (per CETP Module 4.2).
• System leak checks (per CETP Module 4.2).
• As required by local jurisdictional authorities, any changes in the
system design made during the course of system installation (per
CETP Module 4.2).
3. Ensure that all of the appropriate manual valves (i.e., globe, angle, or ball)
are open on the bulk storage containers.
4. If the container has manually operated internal valves, make sure that the
Emergency Shutdown system is operational and that internal valves are
opened.
c. For pneumatically operated systems, make sure that there is adequate

pressure (typically 30-70 psig) and that the system is leak free.
d. For cable operated systems, make sure that all cables are operational
88
Procedures
Operation
2. The system is now operational and ready to:
a. Supply a large volume vapor distribution system.
b. Supply LP-Gas vapor to a jurisdictional (OPS) vapor distribution system.
c. Supply liquid LP-Gas to a vaporizer system prior to supplying vapor to the

distribution system (i.e., in systems where vaporizers are installed).
Shutdown
3. Check to see that all of the appropriate manual valves (i.e., globe, angle, or
ball) are closed on the bulk storage container(s).
4. If the container has manually operated internal valves, make sure that these
valves are closed by releasing the pressure in Emergency Shutdown System
(pneumatic) or pulling the manual cable for the system.
Vaporizers
The types of vaporizers and their respective startup, operating and shutdown
procedures vary considerably. Therefore, it is not possible to provide generic
operating procedures or guidelines for this equipment.
Operators of vaporizers should be trained on the specific startup,

operating and shutdown procedures prior to use. Follow all safety
and operating instructions provided by the manufacturer.
Insert the vaporizer manufacturer’s literature in Section 9, Manufacturers’ Equipment

Information.
89
for LP-Gas Storage Facilities General Maintenance and
Inspection Requirements
Section 6: General Maintenance and Inspection Requirements
This section of the handbook is intended to provide owners or operators of propane systems
the information necessary to comply with the general requirements of NFPA 58, Chapter 14
for maintaining the mechanical integrity of an LP-Gas bulk plant through maintenance
procedures (§14.3.1) and maintenance manuals (§14.3.2).
A checklist approach for the development of procedures specific to the maintenance of the
transfer system and plant equipment is provided in Section 7. Also, refer to Section 8 of this
handbook for maintenance requirements and guidelines for bulk plant fire protection
equipment.
Maintenance Manuals
Maintenance procedures provided by equipment vendors, industrial codes and persons or

organizations knowledgable about the process may be used as the basis for maintenance
procedure manuals for the related equipment.
Maintenance manuals must include routine inspection and preventative maintenance

procedures and schedules.
Maintenance Procedures
• Maintenance procedures must be in written form to be used as the basis for

maintaining the mechanical integrity of LP-Gas systems.
• Whenever a change in equipment or the system occurs, the affected maintenance

procedure(s) must be updated.
Maintenance Record Keeping
Maintenance records provide the tracking and documented verification that the facility is
being properly maintained and in a safe condition in accordance with NFPA 58.
• Record Storage - Maintenance records for all fixed equipment used to store and
transfer LP-Gas must be kept at each facility. For unattended facilities, these
records can be maintained at the unattended facility or another designated location.
• Accessibility – These records must be available to maintenance personnel at all

times and to an authority having jurisdiction at any time during normal business
hours.
90
• Retention – Maintenance records must be retained for the life of the equipment.
Sample charts for preventive maintenance record keeping (see Chart 6.1) and for logging
equipment repairs (see Chart 6.2) are provided at the end of this section.
Maintenance Personnel - Training
• Individuals performing maintenance on the LP-Gas systems must be trained in the

hazards of the system.
• Maintenance personnel also must be trained in the maintenance and testing

procedures applicable to the systems or equipment on which they are working.
• In order to perform the maintenance procedures, all maintenance contractors must

train the personnel under their supervision as noted in the previous two
requirements, or make sure that personnel working on a system or LP-Gas
equipment are under the supervision of a properly trained individual.
Physical Protection of Equipment
The following bulk plant equipment must be physically protected against damage due to
impact from vehicles or to prevent accidental releases of LP-Gas:
• LP-Gas containers and systems incorporating LP-Gas containers.
• Aboveground piping, which also must be properly supported.
• Dispensers.
• Container openings equipped with shutoff, internal or backcheck valves must be

plugged or capped.
Container Condition
• Containers showing excessive denting, bulging, gouging, or corrosion shall be

removed from service.
91
Corrosion Control
Aboveground Containers
• Aboveground containers must be painted to protect against atmospheric

corrosion.
• The portion of an ASME container that comes in contact with saddles or

foundations (including masonry) must be protected against localized
corrosion by coating the affected area or by some other means (e.g., felt,
weather stripping).
• Where necessary, non-metallic materials must be provided with protection to

prevent deterioration due to atmospheric or chemical exposures. Corrosion
protection of non-metallic materials should be provided in accordance with
accepted engineering practice.
Underground and Mounded Containers
• For underground or mounded equipment, all metallic components must be

coated and protected by cathodic protection systems to minimize corrosion..
• Sacrificial cathodic protection systems must be tested according to the

requirements of §6.17.3.1 and §6.17.3.2. Tests must be documented and the
results of the two most recent tests must be retained.
• Impressed current cathodic protection systems must be inspected and tested

as follows:
• Test all sources of impressed current every two months.

• Inspect and test impressed current system installations annually.
• Underground metallic piping must be isolated from underground and

mounded containers with dielectric unions or fittings to prevent possible
corrosion.
• For mounded containers, the mounding material (e.g., earth, sand, fillers)
must be a non-combustible and non-corrosive material. Control measures
must be used to prevent possible erosion of mounding materials.
• For partially underground, unmounded ASME containers, the corrosion

protection must extend for a vertical distance of at least 3 inches above the
surface of the fill. The aboveground portion of the container must be painted.
• Underground or mounded containers installed within 10 feet of a public

vehicle thoroughfare or designated parking location shall be provided with
92
vehicle barrier protection for the fitting housing, container connections and
piping. Protection must conform to the requirements of NFPA 58, § 3.3.79
and § A.3.3.79.
Containers and Appurtenances
NFPA 58 provides for a number of general maintenance requirements associated with

containers in order to allow their continued used. The important elements required by
Chapter 14 of the Code include:
• Steel containers that have been involved in a fire and show no signs of distortion
must be requalified before being placed back in service.
o DOT containers must be requalified by either a DOT-approved repair facility

or by a cylinder manufacturer of that type cylinder.
o ASME containers must be retested using the hydrostatic test procedure that
was applicable at the time of the original fabrication.
o For both DOT and ASME containers involved in a fire, the appurtenances
must be replaced by qualified personnel.
• Aluminum DOT cylinders that have been involved in a fire must be permanently
taken out of service.
• DOT stationary cylinders that are filled at the customer’s location must be:
o Requalified in accordance with DOT requirements; or
o Visually inspected within 12 years of the date of manufacture and every 5

years thereafter. Visual inspection requirements, including documentation,
are detailed in §5.2.3.4 of NFPA 58.
Additional maintenance requirements for container appurtenances are as follows:
• Gaskets for container appurtenances and the system piping must be resistant to the
action of LP-Gas. Furthermore, gaskets must be replaced whenever a flange is
opened. Other detailed gasket requirements are defined in §5.7.1.4. of NFPA 58.
• Pressure Relief valves and discharge piping must be protected to minimize the
entrance of water or extraneous materials through the use of rain caps or any other
effective means that do not affect their operability.
93
Emergency Shutoff Valves
• Emergency valves must actuate when a hose pull away occurs that causes a break
in the fixed piping system.
• Emergency shutoff valves (ESVs) and backflow check valves that are required by the
Code must be tested annually for their functionality. ESVs must be specifically
tested for:
o Manual shutoff from a remote location.

o Manual shutoff at the installed location.
The results of these tests must be documented (see sample Chart 6.3 at the end of
this section). The Code does not set requirements for the retention and maintenance
of these test results. Therefore, you should check with established company policy
for the manner in which and the length of time that these records should be kept.
• Temperature-sensitive elements (i.e., thermal links) cannot be painted nor have any
ornamental finishes applied after they have been manufactured.
Hose Inspection and Maintenance
Hose assemblies must be inspected prior to each use for leakage or damage that could
impair their integrity. Hoses must be inspected at least annually.
When inspecting the hose assembly, look for:
• Damage to the outer cover that exposes the reinforcement.

• Kinked or flattened hose.
• Soft spots or bulges in the hose.
• Damaged couplings (including loose bolts, missing parts and slippage).
• Leakage.
Leaking or damaged hose assemblies must be immediately repaired or removed from

service.
The Code does not set requirements for the documentation, retention and maintenance of
hose inspection results. Therefore, you should check with established company policy.
94
Chart 6.1 (Sample)

Preventive Maintenance Records
Company: ______________ Location: ___________________________ Year: _______
Equipment Procedure Frequency Dates

Performed
Propane Inspect belt/coupling; grease pump Insert Per Mfg.
Pump Recommendations
Propane Inspect belts; change oil & filter Insert Per Mfg.
Compressor Recommendations
Hoses Inspect for cracks, cuts, gouges, wear and Insert Per company
other damage policy
Others, etc.
95
Chart 6.2 (Sample)

Fixed Equipment Log
Repairs, Replacements and Unscheduled Maintenance
Company: ______________ Location: __________________________ Year: _________
Equipment Maintenance/Repair/Replacement Date

Procedure Performed
96
Chart 6.3 (Sample)

ESV & Back Check Valve Testing Log
Company: ______________ Location: ___________________________ Year: _______
Plant Liquid Vapor Acceptable* Corrective Action

Location Service Service () (if “no” in previous column)
() ()
Yes No
Bobtail #1
Bobtail #2
Bobtail #3
Transport Unloading
Transport Loading
Railcar Unloading
Railcar Loading
Bulk Storage #1
Bulk Storage #2
Bulk Storage #3
Others, etc.
* Based on visual inspection of thermal link (no paint), manual shutoff from remote location,
manual shutoff at installed location, and/or positive shutoff by back check valve
97
for LP-Gas Storage Facilities Maintenance & Inspection
Checklist Procedure
Section 7: Maintenance & Inspection Checklist Procedure
NFPA 58 requires that bulk plants and industrial plants have maintenance procedures that are
documented and readily available (§14.3.1 and 14.3.2). This section provides guideline
maintenance and inspection procedures that will provide the basis for maintaining the
mechanical integrity of LP-Gas Systems.
Scope and Application of Section
While maintenance and inspection procedures are typically similar at LP-Gas Bulk Plants and
Industrial Plants, the equipment can vary in size (i.e., storage capacity), design, layout,
equipment complexity or function (e.g., rail unloading facilities, cylinder filling operations, on-site
commercial dispensers). Similar to the operating procedures in Section 5, this handbook
section should be considered to be a “template” for the maintenance and inspection activities
conducted at any specific LP-Gas storage facility. Additions, modifications or deletions to these
procedures could be necessary. Therefore, owners or site management/supervisors should
consider site-specific features and conditions that need to be included, modified or deleted in
the information in this section in order to accurately reflect local operations and conditions. With
these changes, operators, technicians, drivers and other site personnel can use this document
as the maintenance procedures required by NFPA 58.
Although NFPA 58 references the need for documented maintenance and inspection
requirements with respect to refrigerated storage, marine and pipeline LP-Gas systems, these
systems (which can vary significantly in design and complexity) come under the authority of
other jurisdictions which have very specific and detailed requirements.
IMPORTANT: All bulk plant maintenance and inspections should conform to equipment
manufacturers’ instructions as they apply to specific equipment installation and maintenance
procedures.
Manufacturer's literature provides the recommended procedures for maintenance and repair of
equipment specific to your facility. Owners and managers/supervisors must obtain that
information and include it in Section 9 of this handbook (“Manufacturers’ Equipment
Information”) for use by operators, technicians, drivers and other personnel in carrying out their
responsibilities. Review the information provided to determine the appropriate action to take for
inspections, maintenance and repairs.
98
Checklist Procedure
Content of Section
The chart below is a guide to easily identify which equipment in the facility is subject to
maintenance and inspection requirements. Applicable CETP modules are included in the table
for easy reference to further instructional information and materials.
The “CETP-2014 Reference” directs the user to the related module of the training materials
developed by PERC, having a 2014 copyright date.
For CETP-2014, the references are constructed such that the first three letters designate the
course, followed by the applicable module and lesson (e.g., BPP-7-1).
 BPP - Basic Practices and Principles of Propane

 PDO - Propane Delivery Operations and Cylinder Delivery
 BDO - Bobtail Delivery Operations
 BPO – Basic Plant Operations
 3.6 & 3.7 - Performing Railcar Product Transfers and Maintaining DOT Intermodal (IM)
Tanks
 4.1 - Designing and Installing Exterior Vapor Distribution Systems
 4.2 - Placing Vapor Distribution Systems and Appliances into Operation
CETP-2014 Check
Topic Reference (If Applicable)
Bulk Storage Containers BPP-7-1
Piping -
Liquid Pumps -
Bulkheads BPP-7-1
Vapor Compressor -
Tank Car Unloading Tower BPP-7-1
Scales -
Meters (Retail Sales Only) -
Vaporizers -
Regulators -
Electrical Systems -
99
Checklist Procedure
Maintenance and Inspection Procedural Checklist
This section provides a bulk storage facility maintenance and inspection checklist detailing
some of the many preventative maintenance and inspection steps that can be conducted in
typical bulk storage facility and large volume vapor distribution systems.
This checklist is based on the 2014 Edition of NFPA 58. If your facility is not equipped with an
item on this checklist, refer to the edition of NFPA 58 that was applicable at the time of
installation. If the edition in effect did not require the item on the checklist, mark the “N/A” (not
applicable) box and note the referenced edition in the “Comments” section.
To use this checklist for guiding and documenting your maintenance and inspection activities,
simply take the actions as directed by the questions and check the appropriate column (i.e., yes,
no, not applicable). If the “no” box is checked, comments describing the corrective action steps
that have been taken must be documented. If additional space is required, separate sheets can
be attached to the checklist.
Refer to Appendix 7.1 at the end of this section for additional guidance for completing
the checklist.
100
Checklist Procedure
Inspection / Maintenance Item Yes No N/A Comments

1. Bulk Storage Containers
Tank#:
Manufacturer Serial #:
Manufacturer Name:
Year Built:
(A) Construction—Code Compliance
Is the Manufacturer’s Data Plate secured and
  
legible?
Is the data plate free of corrosion?   
Is the pressure rating proper for the product?   
(B)Container – Condition and Markings
Are aboveground tanks properly painted?   
Are containers free of excessive corrosion
  
damage, dents, gouges or other damage?
Are all container markings and decals in
  
accordance with NFPA 58?
(C) Container Foundations
Are foundations in good condition?   
Are containers/saddles free of corrosion at
  
masonry contact areas?
Are saddle pads in good condition?   
(D) Container Fittings
Are all container openings (except relief valve
connections) equipped with proper fixed
  
restriction, back check, or internal valves and
shutoff valves?
Are connections on containers greater than
2,000 gallon water capacity marked “vapor” or   
“liquid”?
101
Checklist Procedure

(D) Container Fittings (cont’d)
Are all fittings that are subject to container
pressure rated for at least 250 psig working   
pressure?
Are all unused openings plugged or capped?   
Are all fittings leak-free?   
(E) Container Gauges
Are pressure gauges in good condition and
suitable for 250 psig service (such as a range   
of 0 - 400 psig)?
Are thermometers in good condition?   
Are liquid level gauges arranged and installed
so that the liquid level can be accurately   
determined?
(F) Container Pressure Relief Valves
Is relief valve data legible?   
Is the relief valve marked for use with LP-Gas
  
and labeled by an independent testing agency?
Is the relief capacity sufficient, as determined
  
by NFPA 58?
Do relief valves communicate with the
container vapor space and discharge upward,   
unobstructed to the open air?
Are relief valves on UG containers >2000
gallons water capacity equipped with vent   
stacks of proper diameter and length?
Do relief valves or vent stacks have loose-

fitting protective caps or closures to prevent   
entry of foreign matter?
Are weep holes for moisture drainage open and
  
is gas impingement of the container prevented?
102
Checklist Procedure

(G) Container - Internal Valves
Are the valve body seams leak-free?   
Are operating cables working correctly?   
Is the pneumatic control system in good
  
working condition?
Are hydraulic operators in good working
  
condition?
Is the thermal element intact and free of paint?   
(H) Container - Emergency Shut-off Valves
Are ESVs in good working condition and leak
  
free?
Has an annual test been performed and
  
documented as required by NFPA 58?
Are operating cables working correctly?   
  
working condition?
Are remote emergency shutoff devices
between 25 and 100 feet from the ESV and   
within the path of egress?
Are remote emergency shutdown stations
  
identified with a sign?
Is the thermal element intact and free of paint?   
(I) Container - Manual Shut-off Valves
Are valves located so that they can be easily
reached during normal operations and in an   
emergency?
Are valves in good condition and leak-free?   
Do valves have the proper service pressure
rating, equal to or greater than the maximum   
allowable working pressure of the container?
103
Checklist Procedure

(J) Container - Catwalks and Stairways
Are stairways well anchored and supported?   
Are catwalk railings provided and in good
  
condition?
Does decking design offer drainage and
  
prevent accumulation?
(K) Container – Presence of Combustibles
Is the area within 10 feet of the containers free
of weeds, long grass, rags, paper, wood or   
other loose or piled combustible debris?
(L) Underground ASME Storage Tank
Is protection against vehicular damage
provided for the fitting housing, housing cover,   
tank connections and piping?
Is the container protected against corrosion by
the following means:
a.) An external coating on the tank?   
b.) Cathodic protection?   
104
Checklist Procedure

2. Piping
(A) Condition of Pipe and Paint
Are aboveground pipes properly painted?   
Are pipes free of corrosion damage, dents,
  
gouges or other damage?
Are pipes adequately supported?   
Are pipes adequately protected against physical
  
damage by vehicles?
Are pipes properly marked “vapor” or “liquid” or
  
color coded accordingly?
(B) Pipe Fittings
Are all flanges and fittings properly sized for the
pressure rating, equal to or greater than the
  
maximum allowable working pressure of the
system?
Are all stainless steel flex connectors in good
working condition (i.e., reinforcement braid is not   
damaged)?
Are all flow indicators and sight checks in proper
  
working condition and leak-free?
Are all fittings and pipes leak-free?   
(C) Hydrostatic Relief Valves
Are hydrostatic relief valves installed in each
section of piping in which liquid can be isolated   
between shut-off valves?
Are hydrostatic relief valves approved for use
  
with LP-Gas?
Do the hydrostatic relief valves have pressure
  
settings between 400 - 500 psig?
(D) Piping - Manual Shut-off Valves
emergency?
Do valves have the proper pressure rating,
equal to or greater than the maximum allowable   
working pressure of the system?
(E) Underground Piping
Is metallic underground piping protected against
corrosion by the following means
a.) An external coating on piping?   
b.) Cathodic protection?   
Is metallic underground piping isolated from
  
underground containers?
105
Checklist Procedure

3. Liquid Pump
(A) General
Are pumps free of corrosion or other damage?   
Are pump pads and/or foundations in good
  
condition and properly supporting the pumps?
Are base plate bolts in place and properly
  
securing the pump to that foundation?
Are the pumps properly lubricated?   
Are strainers in good working condition (i.e.,
  
strainer screens free of debris) and leak-free?
Are hydrostatic relief valves installed in the
appropriate location and in good working   
condition?
working condition (i.e., reinforcement braid is   
not damaged)?
Are fittings and piping associated with the
  
pump leak-free?
(B) Pump Drive Components
Are drive belts properly aligned and in good
  
working condition?
For shaft coupling-driven pumps, are shaft
  
couplings properly aligned?
For shaft coupling-driven pumps, are spacing
  
bushings in good working condition?
For gear reduction-driven pumps, are universal
joints and couplings properly aligned and in   
good working condition?
Are drive belt guards in place and secure?   
(C) Pump Gauges
Are pressure gauges in good condition (i.e., 0 -
  
400 psig)?
(D) Automatic Bypass Valves
Are bypasses in good working condition and
  
leak-free?
Are bypasses set at the appropriate pressure
  
differential?
(E) Pump – Manual Shut-off Valves
emergency?
equal to or greater than the maximum   
allowable working pressure of the system?
106
Checklist Procedure

4. Bulkheads
(A) General
Are bulkheads properly protected against
  
vehicular damage?
Are bulkheads (i.e., structure and foundation) in
good condition and properly supporting the
  
bulkhead, especially in the event of an
attempted pull-away?
(B) Bulkheads- Piping and Fittings
Are pipe nipples and couplings that are
attached to the bulkhead in good working   
condition and free of excessive wear?
pressure rating, equal to or greater than the
  
system
not damaged)?
Are all flow indicators and sight checks in
  
proper working condition and leak-free?
condition?
(C) Bulkheads - Emergency Shut-off Valves
(ESVs)
Are ESVs in good working condition and leak-
  
free?
  
documented as required by NFPA 58
Are operating cables operating correctly?   
  
working condition?
107
Checklist Procedure

(C) Bulkheads - Emergency Shut-off Valves
(ESVs) (Cont’d)
  
(D) Bulkheads - Hoses
Are the hose covers free of exposed
  
reinforcement?
Is wire braid reinforcement free of kinks and not
  
flattened?
Are hoses free of soft spots when not under
pressure, show no bulging under pressure, and   
have no loose outer coverings?
Are hose coupling assemblies secure and in
  
Are the ACME threads, O-rings, or gaskets in
good working condition (i.e., showing little sign   
of excessive wear)?
(E) Bulkheads – Manual Shut-off Valves
Are valves located so that they may be easily
emergency?
Do the valves have the proper pressure rating,
equal to or greater than the maximum   
allowable working pressure of the system?
108
Checklist Procedure

5. Vapor Compressor
(A) General
Are compressors free of corrosion or other
  
damage?
Are compressor pads and/or foundations in
good condition and properly supporting the   
compressors?
Are base plate bolts in place and securing the
  
compressor to that foundation?
Are the compressors properly lubricated?   
Is the crankcase oil properly filled?   
Is the crankcase oil pressure properly set?   
Has the oil filter been changed at the
  
manufacturer’s recommended interval?
Are strainers elements in good working
condition (i.e., strainer screens free of debris)   
and leak-free?
Are pressure relief valves installed in the
condition?
not damaged)?
Are all back check valves in proper working
  
condition and leak-free?
Are fittings and piping associated with the
  
compressor leak-free?
(B) Compressor Drive Components
Are drive belts properly aligned, tension
  
properly set, and in good working condition?
For direct drive compressors, are shaft
couplings properly aligned and in good working   
condition?
Are drive belt guards in place and secure?   
(C) Compressor Gauges
Are pressure gauges (suction and discharge) in
  
good condition (i.e., 0 - 400 psig)?
109
Checklist Procedure

(D) Compressor – Manual Shut-off Valves
emergency?
equal to or greater than the required working   
pressure of the system?
110
Checklist Procedure

6. Tank Car Unloading Tower
(A) Tower Foundations
Are foundations in good condition?   
(B) Tower- Piping and Fittings
pressure rating equal to or greater than the
  
system?
not damaged)?
Are all flow indicators and sight checks in
  
proper working condition and leak free?
condition?
(C) Towers - Emergency Shut-off Valves
(ESVs)
Are ESVs in good working condition and leak-
  
free?
Are ESVs and/or back checks (including
thermal release) on riser ends of the liquid   
hoses in good working condition?
Are ESVS on riser ends of the vapor hose
(including thermal release) in good working   
condition?
  
documented as required by NFPA 58?
  
working condition and free of leaks?
  
111
Checklist Procedure
Inspection/ Maintenance Item Yes No N/A Comments

(D) Tower - Hoses and Loading Arms
Are the hose covers in good condition to
  
prevent exposure of the reinforcement?
  
flattened?
  
of excessive wear)?
Are loading arms leak-free and in good working
  
condition?
Are the loading arm swing-joints properly
  
lubricated?
Are all factory installed protective guards in
  
place and secure?
(E) Tower – Manual Shut-off Valves
emergency?
equal to or greater than the required working   
pressure of the system?
112
Checklist Procedure
Inspection/ Maintenance Item Yes No N/A Comments

7. Scales
(A) General
Has the scale(s) been checked periodically
  
using a certified/standard dead weight?
Is the scale(s) properly calibrated and been
certified by the proper authority having   
jurisdiction?
Have all loops, pivots, and bearings been
  
periodically lubricated?
Are the scale pit(s) and/or platform(s) free of
  
any debris?
(B) Automatic Shut-off System
Are all actuators and control valves leak-free
and in good working condition (i.e., proper fluid   
levels and proper alignment with scale)?
Are all sensing lines leak-free and in good
working condition (i.e., free of kinks and proper   
alignment with the scale)?
(C) Hoses
  
reinforcement?
  
flattened?
  
of excessive wear)?
113
Checklist Procedure

8. Meters (For Retail Sales Only)
(A) General
Is the meter(s) properly calibrated or “proved”
  
at the appropriate time intervals?
Is the seal(s) in place by the appropriate
  
authority having jurisdiction?
Is the meter in good working condition and free
  
of leaks?
Has the strainer been properly cleaned out of
  
any debris?
(B) Hoses
  
reinforcement?
  
flattened?
  
of excessive wear)?
Are pull-away couplings in place and in good
  
working condition?
114
Checklist Procedure

9. Vaporizers
(A) General
Is the vaporizer(s) leak-free and in good
  
working condition?
Have pilot lights been cleaned on a regular
  
basis?
On a periodic basis, have all strainers been
  
cleaned at the inlet side of the vaporizer(s)?
Have heavy ends been cleaned from the
  
vaporizer(s) and/or separator tank?
Have the burner openings, thermostat, and flue
  
been cleaned?
Is the vaporizer(s) located in accordance with
  
NFPA 58?

10. Regulators
(A) General
Is the first-stage or high-pressure regulator
directly attached by flexible connectors to the
  
vaporizer outlet or to the interconnected piping
of manifolded vaporizers?
Are all first-stage and high-pressure regulators
  
installed outside of buildings?
Are all regulators that are outside of buildings
installed and protected so that their operation
will not be affected by environmental elements   
(e.g., freezing rain, sleet, snow, ice, mud or
debris) or insects?
Is the point of discharge on the regulator’s relief
device at least 3 feet horizontally away from
  
any building opening that is below the level of
the discharge?
Is the point of discharge on the regulator’s relief
device located at least 5 feet in any direction
  
from any source of ignition or mechanical
ventilation air intakes?
115
Checklist Procedure

11. Electrical Systems
(A) General
Are all electrical components and wiring in
compliance with Table 6.23.2.2 (Electrical Area   
Classification) in NFPA 58?
Are electrical control switches and wiring in
compliance with Class 1, Group D, Division 1
or 2 (where applicable) in compliance with   
Table 6.23.2.2 (Electrical Area Classification) in
NFPA 58?
Are pump and/or compressor switches readily
  
accessible to the operator?
Are electrical controls for equipment clearly
marked or color-coded to indicate the on and   
off (stop) positions?
Is the electrical emergency shutdown located
not less than 20 ft (nor more than 100 ft) from
  
any dispensing devices, and prominently
labeled?
Is electrical wiring, in Division 1 or 2 areas,
installed in rigid conduit? Class 1, Group D in   
flexible sections?
For electric motors, are flexible connectors
Class 1, Group D, Division 1 or 2 where   
applicable?
Are all seal-off fixtures filled with suitable putty
  
and installed in the appropriate locations?
116
Checklist Procedure
Appendix 7.1
Maintenance and Inspection Procedural Checklist Guidelines
These guidelines are based on the 2014 Edition of NFPA 58. Check with your supervisor if your
facility or equipment was constructed or installed under a previous Code edition. If the item on
the checklist is not subject to the requirements of the 2014 Edition, refer to the applicable Code
edition for guidance.
Bulk Storage Containers
A. CONSTRUCTION – CODE COMPLIANCE
 Is the Manufacturer’s Data Plate (i.e., nameplate) secured and legible?
 The nameplate should be stainless steel and attached to the container in

such a way that minimizes corrosion of the nameplate and does not
contribute to corrosion of the container.
.
 The nameplate should be located so that it is visible after the container is
installed.
 Where the container is buried or otherwise covered so that the nameplate is

obscured, the information contained on the nameplate can be duplicated and
installed on adjacent piping or on a structure in a clearly visible location.
 Is the data plate free of corrosion?
 See the guidelines for the above inspection point.
 Is the pressure rating proper for the product?
For use in propane service, stationary tanks must have a minimum working
pressure of 250 psig (200 psig for some specific ASME tanks built before 1950).
Check with your supervisor if the minimum working pressure is something other
than 250 psig.
B. CONTAINER – CONDITION AND MARKINGS
 Are aboveground tanks properly painted?
 The container should have a paint/coating system in place that prevents

corrosion (rusting).
 Generally, a light reflecting color paint is preferred unless the system is

installed in an extremely cold climate.
117
Checklist Procedure
 Are containers free of excessive corrosion damage, dents, gouges or other

damage?
 External visual inspection of the shell and heads of the container should
indicate that no loss of wall thickness has occurred on the container, either
generally or locally. If there is any question regarding the potential loss of
wall thickness, a qualified inspector can be employed using appropriate non-
destructive testing techniques.
 Are all container markings and decals in accordance with NFPA 58?
See the first item regarding requirements for the manufacturer’s data plate.
Additionally, all ASME containers that contain unodorized LP-Gas must be
marked “NOT ODORIZED” in letters 4 inches high with a contrasting
background, surrounded by a ½ inch rectangular border.
C. CONTAINER FOUNDATIONS
 Are foundations in good condition?
 The structural supports must be constructed of masonry or another

noncombustible material, and located on concrete or masonry foundations.
They should be free of excessive cracking and have no significant loss of the
structural materials. Footings should be level and stable.
 Are containers/saddles free of corrosion at masonry contact areas?
 The parts of the ASME container in contact with the saddles or foundations
must be coated or protected in some manner to minimize corrosion. No signs
of rust bleeding should be apparent.
 Are saddle pads in good condition?
 The pads should show no signs of excessive deterioration and should have adequate
weather sealing to prevent moisture from accumulating and causing corrosion on the
container.
D. CONTAINER FITTINGS
 Are all container openings (except relief valve connections) equipped with
proper fixed restriction, back check, or internal valves and shutoff valves?
 Check with your supervisor and refer to the Code edition applicable for your installation
for specific requirements.
 Are connections on containers greater than 2,000 gallon water capacity

marked “vapor” or “liquid”?
118
Checklist Procedure
 Labels or color codes are permitted to be on valves. Connections for pressure relief
devices, liquid level gauges and pressure gauges are not required to be labeled.
 Are all fittings that are subject to container pressure rated for at least 250
psig working pressure?
 Possible exception: The requirement could be 200 psig associated with some specific
ASME tanks built before 1950. Check the container nameplate and discuss with your
supervisor if other than 250 psig rating.
 Are all unused openings plugged or capped?
 A blind flange or plugged companion flange is acceptable, also.
 Are all fittings leak-free?
 Check each fitting using a gas detector calibrated for LP-Gas or an ammonia-free leak
testing (soap) solution. No gas should be detected. For the leak test solution, no
bubbles should form. Listen and smell for possible leaks.
E. CONTAINER GAUGES
 Are pressure gauges in good condition and suitable for 250 psig service
(such as 0 - 400 psig)?
 The gauges must be readable, functioning and leak-free. They must be attached directly
to the container opening or to a valve or fitting that is directly attached to the container
opening.
 Are thermometers in good condition?
 Temperature gauges (thermometers) must be readable, functioning and leak-free.
 Are liquid level gauges arranged and installed so that the liquid level can
be accurately determined?
 The gauging devices must be either fixed maximum liquid level gauges or variable
gauges of the slip tube, rotary or float types.
 Bulk storage containers must be equipped with a fixed maximum liquid level gauge to
indicate the maximum filling level.
 ASME containers must have permanently attached markings showing the percentage of
capacity that is indicated by that gauge. These markings must be attached to the
container, immediately adjacent to the fixed maximum liquid level gauge or on the
container nameplate.
119
Checklist Procedure
F. CONTAINER PRESSURE RELIEF VALVES
 Is relief valve data legible?
 Each pressure relief valve must be plainly and permanently marked with the following
information:
+ The pressure in psig at which the valve is set to discharge

(i.e., start-to-leak).
+ Rated relieving capacity (cubic feet per minute).
+ Manufacturer’s name and catalog number.
 Is the relief valve marked for use with LP-Gas and labeled by an
independent testing agency?
 Underwriters Laboratory (UL) or other testing agency markings must be legible on the
valve.
 Do relief valves communicate with the container vapor space and

discharge upward, unobstructed to the open air?
 Self-explanatory.
 Are relief valves on underground containers > 2,000 gallons water capacity
equipped with vent stacks of proper diameter and length?
 The diameter of the vent stack piping must be large enough so as not to restrict
discharge flow.
 The relief valve discharge must be piped upward to a point at least seven (7) feet above
the ground.
 Check with your supervisor if there is any question regarding the installation of vent
stacks.

 Do relief valves or vent stacks have loose-fitting protective caps or
closures to prevent entry of foreign matter?
 Rain caps or other protective devices must be provided to minimize the possibility of
water or other foreign matter from entering into the relief device or any discharge piping.
Where accumulation of water is anticipated, means for drainage must be provided.
 The rain cap or other protective device must be designed to remain in place, except
during discharge, and not restrict discharge flow.
120
Checklist Procedure
 Are weep holes for moisture drainage open and is gas impingement of the
container prevented?
 Weep holes must remain clear in order to prevent accumulation of

moisture/condensation.
 A deflector or other means must be in place to protect the container against

flame impingement resulting from ignited product escaping from the drain opening.
G. CONTAINER – INTERNAL VALVES
 Are the valve body seams leak-free?
 Check each fitting using a gas detector calibrated for LP-Gas or an ammonia-free leak
bubbles should appear. Listen and smell for possible leaks.
 Are operating cables working correctly?
 The cable should be free to move through its entire range without binding.
 The cable should fully open and completely close the valve.
 Is the pneumatic control system in good working order?
 Check the operators to make sure proper functioning (typically, through release of air or
nitrogen pressure and then repressurizing).
 The system should be checked for leaks by pressurizing the system and checking all
connections with an ammonia-free leak testing (soap) solution. For the leak test
solution, no bubbles should form. Listen and smell for possible leaks.
 The operator should fully open and completely close the valve.
 Are hydraulic operators in good working condition?
 Check the operators to make sure proper functioning (typically, through release of
pressure and then repressurizing).
 Is the thermal element intact and free of paint?
 Self-explanatory. Additionally, the thermal element should be free of any coating

(including foreign matter) that could interfere with the proper functioning of the link.
H. CONTAINER- EMERGENCY SHUT-OFF VALVES
121
Checklist Procedure
 Are ESVs in good working condition and leak-free?
 Check for leakage at all body seams, plus the connections to the piping and hose.
Check each fitting using a gas detector calibrated for LP-Gas or an ammonia-free leak
 Test (operate) the closing feature to make sure that it will close and open the valve.
 Has an annual test been performed and documented as required by NFPA

58?
 The valves need to be tested for the following functions:

(Note: Check
for the presence of the thermal element.)
+ Manual shutoff from a remote location.
+ Manual shutoff at the installed location.
 Are operating cables working correctly?
 Check operating cables to make sure they can move through their entire range without
binding.
 Make sure the cable tension is not too tight since that might prevent the valve
from latching properly, or vibration or jarring could cause inadvertent closure during
normal transfer operations.
 Is the pneumatic control system in good working condition?
 Are remote emergency shutoff devices between 25 and 100 feet from the
ESV and within the path of egress?
 Is the remote emergency shutdown station identified with a sign?
 Signs should be visible from the point of transfer and have the words “Propane-
Container Liquid Valve Emergency Shutoff” in block letters at least 2 inches high using
contrasting colors.
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Checklist Procedure
 Is the thermal element intact and free of paint?
 Self-explanatory. Additionally, the thermal element should be free of any coating

(including foreign matter) that could interfere with the proper functioning of the link.
I. CONTAINER – MANUAL SHUT-OFF VALVES
 Are valves located so that they can be easily reached during normal
operations and in an emergency?
 Check that valves are located so that they can be accessed and operated without the
use of additional tools or equipment.
 Are valves in good condition and leak-free?
 Check for any excessive corrosion or damage to the body.
 Check for leakage at all body seams and the stems/packing, plus the connections to the
piping and hose. Check each fitting using a gas detector calibrated for LP-Gas or an
ammonia-free leak testing (soap) solution. No gas should be detected. For the leak test
 Check for loose or missing hand-wheels or levers.
 Some manual shut-off valves have a small hydrostatic relief valve installed in them. If a
relief valve is present, be sure the outlet is clear and unrestricted. Be sure the rain cap
is in place.
 Do valves have the proper service pressure rating, equal to or greater than
the maximum allowable working pressure of the container?
 Check to make sure that the pressure rating stamped on the valve is no less than 250
psig. Again the possible exception is that the requirement could be 200 psig associated
with some specific ASME tanks built before 1950. Check the container nameplate and
discuss with your supervisor if other than 250 psig rating.
J. CONTAINER – CATWALKS AND STAIRWAYS
 Are stairways well anchored and supported?
 Check anchor bolts to make sure they are firmly attached and have not experienced
excessive corrosion. Supports and handrails are in place and stable.
 Are catwalk railings provided and in good condition?
 Per OSHA standards ( §1910.23), a standard railing consists of a top rail, middle rail,
and posts, and has a height of 42 inches from the upper surface of the top rail to the
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Checklist Procedure
platform floor. The top rail must be smooth for the entire length.
 Check that the railings are in place, properly anchored, stable and free of excessive
corrosion in order to provide fall protection for workers.
 Does decking design offer drainage and prevent accumulation?
K. CONTAINER – PRESENCE OF COMBUSTIBLES
 Is the area within 10 feet of the container(s) free of weeds, long grass, rags,
paper, wood or other loose or piled combustible debris?
L. UNDERGROUND STORAGE TANKS
 Is protection against vehicular damage provided for the fitting housing,

housing cover, tank connections and piping?
 Crash protection must be in place where LP-Gas storage equipment can be subjected to
vehicular traffic.
 Is the container protected against corrosion by an external coating on the

tank and cathodic protection?
 When inspecting the components of the tank that are visible aboveground, check those
portions of the coating system (e.g., paint) for damage.
 When taking a tank-to-soil voltage reading, a minimum -0.85 voltage reading must be
measured and maintained.
Piping
A. CONDITION OF PIPE AND PAINT
 Are aboveground pipes properly painted?
 Piping should have paint and coatings systems in place that are not damaged and
provide protection against external corrosion.
 Are pipes free of corrosion damage, dents, gouges or other damage?
 Check for excessive rust or corrosion that would indicate metal loss on the piping.
Particular attention should be given to the areas around supports for localized corrosion.
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Checklist Procedure
 Check for dents or gouges that could reduce the wall thickness of the pipe.
 Check for evidence of localized pitting, especially at weld seams.
 Check for any indications of fire damage.
 Are pipes adequately supported?
 Check that supports are in place so that the piping is not bending or flexing in a manner
that would appear to cause stress on the piping and subsequently cause leakage.
 Are pipes adequately protected against physical damage by vehicles?
 Crash protection must be in place where piping can be subjected to vehicular traffic.
 Are pipes properly marked “vapor” or ”liquid”, or color coded accordingly?
 Self-explanatory. Note: Labels are permitted to be on valves.
B. PIPE FITTINGS
 Are all flanges and fittings properly sized for the pressure rating, equal to
or greater than the maximum allowable working pressure of the system?
 Piping, flanges and fittings that can contain liquid LP-Gas, and that can be isolated by
valves and require hydrostatic relief valves, must be designed for an operating pressure
of 350 psig or a pressure that is equivalent to the maximum discharge pressure of any
pump or any source feeding the piping system if it is greater than 350 psig.
 Otherwise, the minimum pressure rating is 250 psig for LP-Gas liquid or vapor at
operating pressure over 125 psig and at or below container pressure.
 The minimum pressure rating is 125 psig for LP-Gas vapor at operating pressure of 125
psig or less.
 Are all stainless steel flex connectors in good working condition (i.e.,
reinforcement braid is not damaged)?
 Check for mechanical or physical damage, excessive corrosion, cracking or bulging.
 Note: Flexible connectors should not be painted.
 Are all flow indicators and sight checks in proper working condition and
leak-free?
 Where installed, sight flow indicators must be either the simple observation type or be
combined with a backflow check valve.
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Checklist Procedure
 Flow indicators cannot be constructed of cast iron.
 The sight indicators should be sufficiently clean and clear to see the flow upon liquid
transfer.
 Check using a gas detector calibrated for LP-Gas or an ammonia-free leak testing
(soap) solution. No gas should be detected. For the leak test solution, no bubbles
should form. Listen and smell for possible leaks.
 Are all fittings and pipes leak-free?
 Check the piping and fittings using a gas detector calibrated for LP-Gas or an ammonia-
free leak testing (soap) solution. No gas should be detected. For the leak test solution,
no bubbles should appear. Listen and smell for possible leaks.
C. HYDROSTATIC RELIEF VALVES
 Are hydrostatic relief valves installed in each section of piping in which

liquid can be isolated between shut-off valves?
 Hydrostatic relief valves should be fitted with rain caps to prevent moisture and debris
from accumulating inside the valve.
 Are the hydrostatic relief valves approved for use with LP-Gas
 Check the stamping on the valve body.
 Do the hydrostatic relief valves have pressure settings between 400 - 500
psig?
 Hydrostatic relief valves designed to relieve pressure in sections of liquid piping between
closed shut-off valves must have pressure settings not less than 400 psig and not more
than 500 psig unless installed in systems designed to operate above 350 psig. In this
case, the settings must be not less than 110% or more than 125% of the system design
pressure.
D. PIPING – MANUAL SHUT-OFF VALVES
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Checklist Procedure
piping and hose. No gas should be detected through normal leak testing techniques.
is in place.
the maximum allowable working pressure of the container?
 Check to make sure that the pressure rating stamped on the valve is no less than 250
psig. Again, the possible exception is that the requirement could be 200 psig associated
with some specific ASME tanks built before 1950. Check the container nameplate and
discuss with your supervisor if other than 250 psig rating.
E. UNDERGROUND PIPING
 Is the metallic underground piping protected against corrosion by an

external coating on the piping and cathodic protection?
 When inspecting the portions of the underground piping system that that are visible
aboveground, those portions of the coating system (e.g., paint) are not damaged.
 When taking a pipe-to-soil voltage reading, a minimum -0.85 voltage reading must be
measured and maintained.
Liquid Pump
A. GENERAL
 Are pumps free of corrosion or other damage?
 Check for excessive external corrosion or mechanical damage to the casing and drive
assemblies.
 Are pump pads and/or foundations in good condition and properly

supporting the pumps?
 They should be free of excessive cracking or significant loss of the supporting materials.
 They should be level and stable, positioned so that there is no misalignment with the
piping system.
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Checklist Procedure
 Are base plate bolts in place and properly securing the pump to that
foundation?
 Are the pumps properly lubricated?
 Lubrication will vary depending on the type of LP-Gas pump. Check the equipment
manufacturer’s instructions for specific lubricants and frequency of lubrication.
 Are the strainers in good working condition (i.e., strainer screens free of
debris) and leak-free?
 Isolate the strainer from the transfer system, bleed off the trapped LP-Gas, and remove
the cylinder and filter screen to inspect and clean to clear of particles and heavy ends.
 Check the inlet and outlet connections, using a gas detector calibrated for LP-Gas or an
ammonia-free leak testing (soap) solution. No gas should be detected. For the leak test
solution, no bubbles should form. Listen and smell for possible leaks. Be sure to also
check that the cover is gas tight.
 Are the hydrostatic relief valves installed in the appropriate location and in
good working order?
 Flexible connectors should not be painted.
 Flexible connectors should not be used to compensate for misalignment with the piping
or to take the place of elbows.
 Note: Check with your supervisor regarding company policies or state/local regulations
to make sure compliance before installing or servicing flexible connectors.
 Are fittings and piping associated with the pump leak-free?
 Check the piping and fittings using a gas detector calibrated for LP-Gas or a leak testing
should appear. Listen and smell for possible leaks.
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Checklist Procedure
B. PUMP DRIVE COMPONENTS
 Are drive belts aligned and in good working condition?
 This should be done when lubrication is scheduled. Check manufacturer’s literature for
additional information.
 Check belts for excessive wear, cracking or weathering.
 For shaft coupling-driven pumps, are shaft couplings properly aligned?
 Self-explanatory. Check manufacturer’s literature for additional information.
 For shaft coupling-driven pumps, are spacing bushings in good working

order?
 Check for excessive wear on the space bushings.
 For gear reduction-driven pumps, are universal joints and couplings

properly aligned?
 Check universal joints or couplings for excessive wear.
 Check alignment of the drive shaft, motor ad gear box. Check the mounts and securing
bolts.
 The gearbox and U-joints should be lubricated per the manufacturer’s instructions.
 Are drive belt guards in place and secure?
C. PUMP GAUGES
 Are pressure gauges in good condition (i.e., 0 - 400 psig)?
 The gauges must be readable, functioning and leak-free.
 Check manufacturer’s literature for additional information.
D. AUTOMATIC BYPASS VALVES
 Are bypasses in good working condition and leak-free?
 An automatic bypass valve and piping circuit is required; a manual bypass circuit is
optional.
 If the bypass valve or recirculating device is equipped with a shut-off valve, a secondary
device is required and designed to do one of the following:
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Checklist Procedure
+ Operate at no more than 400 psig.

+ Operate at a pressure of 50 psig above the operating pressure
when the design pressure exceeds 350 psig.
 The secondary device must be designed and installed such that:

+ It cannot be rendered inoperative.
+ It discharges into either the storage container or the pump inlet.
 Are bypasses set at the appropriate pressure differential?
 The bypass valve should be set at least 15 - 20 psig below the pump’s internal relief
valve setting.
 The bypass valves should not be set for a pressure higher than the differential pressure
rating of the pump or higher than the maximum 125 psig differential pressure typically
recommended by the manufacturer.
 To determine the automatic bypass opening setting, check the equipment

manufacturer’s instructions.
E. PUMP – MANUAL SHUT-OFF VALVES
piping and hose. No gas should be detected through normal leak testing techniques.
is in place.
the maximum allowable working pressure of the system?
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Checklist Procedure
 Check to make sure that the pressure rating stamped on the valves is consistent with the
maximum design pressure of other components in the pump discharge and bypass
system.
131
Checklist Procedure
Bulkheads
A. General
 Are bulkheads properly protected against vehicular damage?
 Crash protection must be in place where LP-Gas transfer equipment can be subjected to
vehicular traffic.
 Are bulkheads (i.e., structure and foundation) in good condition and

properly supporting the bulkhead, especially in the event of an attempted
pull-away?
 Bulkheads are normally made from steel beams and reinforced concrete. Check for
excessive corrosion of the steel and mechanical damage to the concrete or rebar.
B. BULKHEADS – PIPE AND FITTINGS
 Are pipe nipples and couplings that are attached to the bulkhead in good
working condition and free of excessive wear?
 Check for leakage using a gas detector calibrated for LP-Gas or an ammonia-free leak
 Check the threads for excessive wear or deformation.
psig or less.
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Checklist Procedure
leak-free?
 Sight flow indicators must be either the simple observation type or be combined with a
backflow check valve.
transfer.
 Are hydrostatic relief valves installed in the appropriate location and in

 Hydrostatic relief valves are designed to relieve pressure in sections of liquid piping
between closed shut-off valves, and must have pressure settings not less than 400 psig
and not more than 500 psig unless installed in systems designed to operate above 350
psig. In this latter case, the settings must be not less than 110% or more than 125% of
the system design pressure.
C. BULKHEADS – EMERGENCY SHUT-OFF VALVES
 Will ESVs acuate if a hose pullaway occurs?
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Checklist Procedure

58?

(Note: Check
for the presence of the thermal element.)
 Are operating cables operating correctly?
 Check operating cables to make sure they can move through their entire range without
binding.
 Make sure the cable tension is not too tight since that might prevent the valve from
latching properly, or vibration or jarring could cause inadvertent closure during normal
transfer operations.
 Signs should be visible from the point of transfer.
D. BULKHEADS – HOSES
 Are hose covers free of exposed reinforcement?
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Checklist Procedure
 Is wire braid reinforcement free of kinks and not flattened?
 Are hoses free of soft spots when not under pressure, show no bulging
under pressure, and have no loose outer coverings?
 Are hose coupling assemblies secure and in good working condition?
 Inspect each coupling for slippage, evidenced by misalignment of the coupling on the
hose end, and/or if it is scored or exposed.
 Are the ACME threads, O-rings, or gaskets in good working condition (i.e.,
showing little sign of wear)?
 Check the threads on the hose end adapter or the CTMV filler connection for excessive
wear to the point that the connection leaks with a new O-ring or gasket (see sketch
below). The worn adapter or fitting must be replaced.
E. BULKHEADS – MANUAL SHUT-OFF VALVES
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Checklist Procedure
is in place.
the maximum allowable working pressure of the system?
maximum design pressure of other components in the pump discharge and bypass
system.
Vapor Compressor
A. GENERAL
 Are compressors free of corrosion or other damage?
 Check for excessive external corrosion or mechanical damage to the casing, drive
assembly, suction and discharge piping, liquid trap, strainer and motor.
 Check the cooling systems fins. They must be kept clean and the flywheel must be kept
free of obstructions to allow sufficient air flow and cooling.
 Are compressor pads and/or foundations in good condition and properly

supporting the compressors?
 Note: To prevent damage to the piping network from vibration, the compressor must be
bolted to a solid, level foundation that will fully support both the compressor and its drive
system. This is especially important with large units where heavier vibrations can be
expected.
 They should be level and stable, positioned so that there is no misalignment with the
piping system.
 Are base plate bolts in place and securing the compressor to that
foundation?
 Self-explanatory (see note above).
 Are the compressors properly lubricated?
 Lubrication could vary depending on the compressor design and manufacturer. Check
the equipment manufacturer’s instructions for specific lubricants and frequency of
lubrication.
 Before starting the compressor, check the crankcase for leaks, especially around the
flywheel-end of the crankshaft, the dipstick, and the breather valve assembly. When
checking the breather valve assembly, be sure that it is clear and free of any dirt or
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Checklist Procedure
trash. If any leaks are noticed, notify your supervisor.
 Is the crankcase oil properly filled?
 Check the oil level in the crankcase before each operation. If the oil level is low, check
the manufacturer's instructions for the type of oil to use and the amount to add.
 Is the crankcase oil pressure properly set?
 Check the oil pressure gauge frequently during every compressor operation. If the oil
pressure is unusually high or low, shut down the compressor and notify your supervisor.
 Has the oil filter been changed at the manufacturer’s recommended

interval?
 Are strainer elements in good working condition (i.e., strainer screens free
of debris) and leak-free?
 Note: Compressor strainers usually have coarser screens than pump strainers.
However, they must be opened and cleaned on a regular basis to prevent them from
being clogged and restricting flow to the compressor.
 While the compressor is not operating, isolate the strainer, bleed off any trapped LP-Gas
and remove the cylinder and filter screen to inspect and clean.
 Check that the connections and the cover are gas tight by using a gas detector
calibrated for LP-Gas or an ammonia-free leak testing (soap) solution. No gas should be
detected. For the leak test solution, no bubbles should form. Listen and smell for
possible leaks.
 Are pressure relief valves installed in the appropriate location and in good
working order?
 The discharge line of most compressors is equipped with a discharge relief valve to
protect the compressor system from damage due to excessively high pressure.
 The valve is usually set to open at a pressure of 250 psig.
 Check the discharge relief valve regularly for leaks and be sure the inside of the valve is
free from corrosion and debris that would prevent the valve from opening and closing
properly.
CAUTION: When inspecting relief valves, use an inspection mirror to check the inside of
the valve. Never look directly into the outlet of any pressure relief valve.
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Checklist Procedure
 If found to be defective, the valve cannot be repaired and must be replaced.
 Discharge relief valves on compressors installed indoors or in enclosed spaces must be

vented to the outside.
 Are stainless steel flex connectors in good working condition (i.e.,

 Flexible connectors should not be used to compensate for misalignment with the piping
or to take the place of elbows.
 Note: Check with your supervisor regarding company policies or state/local regulations
to make sure compliance before installing or servicing flexible connectors.
 Are all back check valves in proper working condition and leak-free?
 Check to see that back check is completely shutting off any and all reverse flow.
 Are fittings and piping associated with the compressor leak-free?
B. COMPRESSOR DRIVE COMPONENTS
 Are drive belts properly aligned, tension properly set and in good working
condition?
 V-belts should depress ½” to ¾” under moderate thumb pressure.
 Check the equipment manufacturer’s instructions if tension or alignment adjustments are

necessary.
 Check for belts for fraying and cracks; replace, if necessary.
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Checklist Procedure
 For direct drive compressors, are shaft couplings properly aligned and in
 Self-explanatory. Check the manufacturer’s instructions for additional information.
 Are drive belt guards in place and secure?
C. COMPRESSOR GAUGES
 Are pressure gauges (suction and discharge) in good condition (i.e., 0 - 400
psig)?
 The gauges must be readable, functioning and leak-free.
 Check manufacturer’s literature for additional information.
D. COMPRESSOR – MANUAL SHUT-OFF VALVES
is in place.
 Do valves have the proper pressure rating, equal to or greater than the
required working pressure of the system?
maximum design pressure of other components in the compressor suction and
discharge systems.
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Checklist Procedure
Tank Car Unloading Tower

A. TOWER FOUNDATIONS
 Are foundations in good condition?
 They should be level and stable.
 Are footings free of settlement?
 The footings should be level and stable, positioned so that no shifting of the tower has
occurred.
B. TOWER – PIPING AND FITTINGS
psig or less.
 Note: Flexible connectors should not be painted.
leak-free?
 Where installed, sight flow indicators must be either the simple observation type or be
combined with a backflow check valve.
transfer.
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Checklist Procedure
 Are hydrostatic relief valves installed in the appropriate location and in

 Check sections of liquid lines between shut-off valves for the presence of these valves.
 Check regularly for leaks and inspect to make sure the valve is free from corrosion and
debris that could prevent the valve from opening and closing properly.
 Hydrostatic relief valves designed to relieve pressure in sections of liquid piping between
closed shut-off valves must have pressure settings not less than 400 psig and not more
than 500 psig.
 Check the piping and fittings using a gas detector calibrated for LP-Gas or an ammonia-
free leak testing (soap) solution. No gas should be detected. For the leak test solution,
no bubbles should appear. Listen and smell for possible leaks.
C. TOWERS – EMERGENCY SHUT-OFF VALVES (ESVs)
 Are ESVs and/or back checks (including thermal release) on riser ends of
the liquid hoses in good working condition?
 Operate the closing feature to make sure that it will close and open the ESV.
 Check to see that back check is fully functional.
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Checklist Procedure
 Are ESVs and/or back checks (including thermal release) on riser ends of
the vapor hose in good working condition?
 Operate the closing feature to Check to see that it will close and open the ESV.
 Check to see that back check is fully functional.

58?
(Note: Check for the presence of the thermal element.)

 Signs should be visible from the point of transfer.
D. TOWER – HOSES AND LOADING ARM
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Checklist Procedure
 Are loading arms leak-free and in good working condition?
 See equipment manufacturer’s instructions for leak testing and preventative

maintenance/inspection requirements.
 Are loading arms swing joints properly lubricated?
 See equipment manufacturer’s instructions for the proper lubricant(s) and the frequency
of lubrication.
 Are all factory installed protective guards in place and secure?
 See equipment manufacturer’s instructions for the required guards and check to make
sure they are in place.
E. TOWER – MANUAL SHUT-OFF VALVES
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Checklist Procedure
is in place.
 Do valves have the proper pressure rating, equal to or greater than the
required working pressure of the system?
 Check to make sure that the pressure rating stamped on the valves is no less than 250
psig.
Scales
A. GENERAL
 Has the scale(s) been checked periodically using a certified/standard dead

weight?
 Check with your supervisor regarding the frequency of checking the scale(s).
 The certified or standard dead weight should be approximately equal to the typical tare
weight of the cylinders being filled plus the LP-Gas contents of one of these cylinders.
 Is the scale(s) properly calibrated and been certified by the proper authority
having jurisdiction?
 Check the scale manufacturer’s instructions for their calibration procedure.
 In most states and jurisdictions, scales must bear current certification decals from
weights and measures officials.
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Checklist Procedure
 Have all loops, pivots and bearings been periodically lubricated?
 Check the scale manufacturer’s instructions for lubrication requirements.
 Note: Do not use oil on scale parts unless instructed to do so by the scale manufacturer.
 Are the scale pit(s) and/or platform(s) free of any debris?
 Check for accumulation of snow, ice, leaves and other debris that could cause the scale
platform to bind and produce an inaccurate scale reading.
 Check and clean these areas frequently.
B. AUTOMATIC SHUT-OFF SYSTEM
 Are all actuators and control valves leak-free and in good working
condition (i.e., proper fluid levels and proper alignment with scale)?
 Also check scale manufacturer’s instructions for any specific or unique requirements and
instructions.
 Are all sensing lines leak-free and in good working condition (i.e., free of
kinks and proper alignment with the scale)?
C. HOSES
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Checklist Procedure
 Inspect for loose or missing bolts or fastenings on bolted hose coupling assemblies.
Meters (For Retail Sales Only)
A. GENERAL
 Is the meter properly calibrated or “proved” at the appropriate time

intervals?
 In most states, meter proving is under the jurisdiction of a state-level government

authority such as the Bureau of Weights and Measures.
 The responsible agency places a seal on the meter when it has been proved and found
to be accurate.
 Note: Many state and local codes require companies to recalibrate meters on a regular
basis. Generally, this is accomplished by filling a volumetric prover (a tank of certified
capacity) through the meter being tested. The reading on the meter is then compared to
the quantity of LP-Gas in the prover and the meter adjusted accordingly. Only personnel
who are properly trained and qualified to prove meters should do so.
 Is the seal(s) in place by the appropriate authority having jurisdiction?
 Check to see that the seal is not broken. If broken, the meter must be proved again and
resealed before it is placed back into service.
 Is the meter in good working condition and free of leaks?
 Be alert for erratic meter operation, obvious over or under registration, increasingly noisy
operation and excessively low delivery rates.
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Checklist Procedure
 Check the seal that is either on the input or the output shaft of the gear train to prevent
the LP-Gas from leaking out of the meter body and entering the register. The seal is
usually a U-shaped packing or O-ring that fits around the drive shaft and is designed to
be replaceable in case it begins to leak.
B. HOSES
 Are pull-away couplings in place and in good working condition?
 Check that the breakaway device is UL 567 approved (Standard Pipe Connectors for
Flammable and Combustible Liquids and LP-Gas) and is capable of retaining liquid on
both sides of the breakaway point. If this not the case, check with your supervisor and
determine whether there is a device in place that provides equivalent protection and has
been approved by the authority having jurisdiction.
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Checklist Procedure
Vaporizers
A. GENERAL
 Is the vaporizer(s) leak-free and in good working condition?
 The specific inspection steps will vary depending on the type of device being used to
heat the liquid LP-Gas and the manufacturer’s design. Refer to the equipment
manufacturer’s instructions for inspection requirements and procedures.
 Have pilot lights been cleaned on a regular basis?
 Refer to the equipment manufacturer’s instructions for the frequency and instructions for
inspecting and cleaning pilots.
 On a periodic basis, have all strainers been cleaned at the inlet side of the
vaporizer(s)?
 Refer to the equipment manufacturer’s instructions for the instructions and suggested
frequency for inspecting and cleaning strainers.
 Have heavy ends been cleaned from the vaporizer?
 Refer to the equipment manufacturer’s instructions for the instructions and suggested
frequency for cleaning heavy ends from the vaporizer.
 Have the burner openings, thermostat and flue been cleaned?
 Is the vaporizer(s) located in accordance with NFPA 58?
 Vaporizers are generally installed outdoors. If the vaporizer is installed in a separate or

attached structure, check with your supervisor for the specific requirements in Chapter
10 of NFPA 58 that are associated with the type of vaporizer in use.
 Vaporizing burners must be installed outside of buildings, per NFPA 58. The minimum
separation distance between a vaporizing burner and container having >2,000 gallons
water capacity is 50 feet. The minimum distance between a burner and container ≤500
gallons is 10 feet, and 25 feet for containers in the 501 – 2,000 gallon range.
Regulators
A. GENERAL
 Is the first-stage or high-pressure regulator directly attached by flexible

connectors to the vaporizer outlet or to the interconnected piping of
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Checklist Procedure
manifolded vaporizers?
 Self-explanatory. (Exception: Flexible connectors are not required for first-stage

regulators that are installed downstream of high pressure regulators.)
 Are all first-stage and high-pressure regulators installed outside of

buildings?
 Are all regulators that are outside of buildings installed and protected so
that their operation will not be affected by environmental elements (e.g.,
freezing rain, sleet, snow, ice, mud or debris) or insects?
 The regulator must be installed such that the vent is protected against water
accumulation in the form of rain, sleet, snow, mud or ground water. Typically, vents and
pipe-aways are pointed downward and the opening protected with a screen.
 The vent must be open to the atmosphere.
 The bonnet cap must be in place and tightened.
 Is the point of discharge on the regulator’s relief device at least 3 feet

horizontally away from any building opening that is below the level of the
discharge?
 Is the point of discharge on the regulator’s relief device located at least 5

feet in any direction from any source of ignition or mechanical ventilation
air intakes?
Electrical Systems
A. GENERAL
 Are all electrical components and wiring in compliance with Table 6.23.2.2
(Electrical Area Classification) in NFPA 58?
 To accurately check ignition source control through assessment of the installation of

electrical equipment, you should be knowledgeable of the requirements in the NFPA 58
Electrical Classification Table in Chapter 6. Also, you need to be familiar with the
definitions of electrical classes, groups and divisions in NFPA 70, National Electric Code.
149
Checklist Procedure
 When classifying the extent of a hazardous area, consider the possible variations in the
spotting of railroad tanks cars and CTMVs at the unloading points.
 Are electrical control switches and wiring in compliance with Class1,

Group D, Division 1 or 2 (where applicable) and in compliance with Table
6.23.2.2 (Electrical Area Classification) in NFPA 58?
 See comment in the previous guideline.
 Are pump and/or compressor switches readily accessible to the operator?
 Generally, NFPA 58 simply requires that a pump or compressor operating control or

disconnect switch be “located nearby”, as stated in Chapter 6. For dispensers, see the
fifth item in this checklist series.
 Are electrical controls for equipment clearly marked or color-coded to

indicate the on and off (stop) positions?
 The designated color (by OSHA) for the off (or stop) position is red.
 Is the electrical emergency shutdown located not more than 20 feet (but
less than 100 feet) from any dispensing devices, and prominently labeled?
 This is a specific requirement in Chapter 6 of NFPA 58 for dispensers.
 The markings for the switches (or breakers) must be visible at the point of liquid transfer.
 Is electrical wiring in Division 1 or 2 areas installed in rigid conduit?

Class1, Group D in flexible sections?
 Self-explanatory. Check with your supervisor if you need additional information

regarding electrical area classifications.
 For electric motors, are flexible connectors Class1, Group D, Division 1 or 2

where applicable?
 Self-explanatory. Check with your supervisor if you need additional information

regarding electrical area classifications.
 Are all seal-off fixtures filled with suitable putty and installed in the
appropriate locations?
 A conduit seal-off fixture filled with a suitable putty must be installed within 18 inches of
any spark producing device within a Hazardous Classified Location, unless the
enclosure is outfitted with a factory seal at the conduit connection.
 A conduit seal-off fixture filled with a suitable putty must be installed where a conduit is
entering or leaving a Hazardous Classified Location (i.e., between the Hazardous
Classified Location dispenser area and the main electrical supply) in order to prevent
150
Checklist Procedure
LP-Gas vapor from entering open wiring.
151
for LP-Gas Storage Facilities Maintenance of
Fire Protection Equipment
Section 8: Maintenance of Fire Protection Equipment
This section of the Handbook provides owners or operators of LP-Gas bulk plants with
an introduction and general guidance for complying with the requirements of NFPA 58
for maintaining fire protection equipment as defined in Chapter 14 (§14.3.3).
References
• NFPA 10, Standard for Portable Fire Extinguishers, 2013 Edition
• NFPA 25, Standard for the Inspection, Testing, and Maintenance of Water-Based
Fire Protection Systems, 2014 Edition
General Requirements
Facilities must prepare and implement a program for all plant fire protection equipment.
Maintenance activities of fire protection equipment must be scheduled so that a
minimum of equipment is taken out of service at any time and is returned to service in a
reasonable time period. NFPA has not defined what “minimum” and “reasonable” mean
in terms of number and length of time. Therefore, site management should make every
effort to meet the intent of the requirement.
8.1 Portable Fire Extinguishers
Portable fire extinguishers must be maintained in accordance with NFPA 10, Standard
for Portable Fire Extinguishers.
Since NFPA 10 provides the detailed requirements regarding the placement,

maintenance, inspection and recharging, this handbook section simply provides an
overview of the basic requirements for placement, maintenance and inspection of fire
extinguishers such that LP-Gas marketers and distributors have a familiarity with the
basic requirements. Additionally, a sample maintenance and inspection recordkeeping
list is provided.
152
Summary of Requirements *This information is not required by Ch. 14 to be

in the maintenance manual.
a) Where cylinders of 1000 lb water capacity or less are stored and are
awaiting use, resale or exchange, the following fire protection
requirements apply:
• At least one approved portable fire extinguisher with a capacity

of 18 pounds dry chemical with a B:C rating must be provided
if the aggregate quantity of LP-Gas stored is more than 720
pounds.
• Retail cylinder exchange locations must have a 10 pound

A:B:C rated fire extinguisher if the aggregate quantity of LP-
Gas stored is more than 720 pounds.
• Fire extinguishers with a UL rating of 40 B:C must be located

no more than 30 feet from the cylinder storage location. Fire
extinguishers with a UL rating of 80 B:C must be located no
more than 50 ft from the cylinder storage location. (Note:
Where fire extinguishers have more then one letter
classification, they can be considered to satisfy the
requirements of that letter.)
b) Fire extinguishers must be located, identified, and be readily accessible

to all employees.
c) A fire extinguisher must be on each vehicle that transports a hazardous

material (LP-Gas).
d) Each fire extinguisher must be maintained in a fully charged and operable

condition at all times.
e) Each fire extinguisher must be visually inspected monthly by a

designated employee. Each monthly inspection must be recorded on a
tag or label affixed to the fire extinguisher, showing the date of inspection
and initials of inspector.
f) An annual maintenance check must be performed on each fire

extinguisher by an authorized service company. Each maintenance
check must be recorded on a label affixed to the extinguisher by the
service company.
g) Each location must maintain a record of the monthly inspections and

annual maintenance, and retain this record for one year after the last
entry or the life of the shell of the extinguisher, whichever is less (see
153
sample Chart 8.1).
h) Each location must provide training to all employees upon initial hiring
and at least annually thereafter to familiarize them with the general
principles and proper operation of the fire extinguisher.
154
Chart 8.1 (Sample)

Maintenance & Inspection Record
Portable Fire Extinguishers
Company: _________________ Location: ___________________ Year: ______
Qualified
Individual or
Extinguisher Inspection or Certifying Signature
(# or Location) Maintenance Performed Corrective Action Date (Owner Rep.)
Company
(Monthly / Annual)
Name
(as applicable)
155
8.2 Water-Base Fire Protection Systems
Water-base automatic fire extinguishers must be maintained in accordance with

NFPA 25, Standard for the Inspection, Testing, and Maintenance of Water-Base
Fire Protection Systems.
Water-base fire protection systems are designed and built by various

manufacturers and construction firms. Since they are usually unique in design
and operation, manufacturer recommendations should be consulted for testing
and maintenance.
The following information and material are provided for those plants where water-
base fire protection systems have been installed due to jurisdictional
requirements.
Summary of Requirements
a) NFPA 25 stipulates the required testing and maintenance items. These

requirements will be dependent upon the type and design of the systems
that have been installed.
b) These inspections and maintenance requirements are required to be

performed on a daily, weekly, monthly, quarterly or annual basis,
depending on the specific type of system and components utilized in
system.
c) Annual inspections of all types of systems must be performed by a

qualified individual.
d) Records of the inspection and maintenance (including repairs) must be

maintained at the location (see sample Chart 8.2).
156
Chart 8.2 (Sample)

Maintenance & Inspection Record
Water-Base Fire Protection Systems
Company: _____________________ Location: _____________________ Year: ______
Qualified
Individual or
Equipment Procedure Performed
Certifying Date Signature
Description (Owner Rep.)
Company
Name
157
for LP-Gas Storage Facilities Manufacturers’ Equipment
Information
Section 9: Manufacturers’ Equipment Information
Section Purpose
Section 7 of this handbook provided a checklist of maintenance and inspection

procedures for maintaining the mechanical integrity of LP-Gas Systems. As mentioned
previously, maintenance and inspection procedures are typically similar at LP-Gas Bulk
Plants and Industrial Plants. However, equipment can vary in capacity, design or
complexity. Therefore, all equipment inspections and maintenance procedures should
be conducted as specified in the equipment manufacturers’ instructions.
Manufacturer's literature provides the recommended procedures for installation,

operations, maintenance and repairs on equipment specific to your facility.
Owners and managers/supervisors must obtain that information and include it within this
section of this handbook for ready reference and use by operators, technicians, drivers
and other personnel in carrying out their responsibilities.
Plant personnel should review this information to determine the appropriate action to
take when operating equipment or performing equipment inspections, maintenance and
repairs.
► ACTION ◄
INSERT THE MANUFACTURERS’ EQUIPMENT INFORMATION

THAT IS SPECIFIC TO YOUR LP-GAS BULK STORAGE FACILITY
IN THIS SECTION OF THE HANDBOOK, BEHIND THIS PAGE.
158
Operations & Maintenance Handbook Appendix A
for LP-Gas Storage Facilities References
Appendix A: References
The documents or portions of them, that are listed in this appendix are referenced in or
used to perform the procedures noted in one or more sections within this handbook.
 American Petroleum Institute, API-ASME Code for Unfired Pressure Vessels for
Petroleum Liquids and Gases, Pre-July 1, 1961.
 American Society of Mechanical Engineers, “Rules for the Construction of

Unfired Pressure Vessels,” Section VIII, ASME Boiler and Pressure Vessel Code,
2010.
 Association of American Railroads, Field Manual of the Interchange Rules (#70,

88, 89, and 90).
 Association of American Railroads, Manual of Standards and Recommended

Practices, Section c, Part III, Specifications for Tank Cars, (M-1002).
 Canadian General Standards Board, CAN/CGSB 43.147-2005, Construction,

Modification, Qualification, Maintenance and Selection and Use of Means of
Containment for the Handling, Offering for Transport, or Transporting of
Dangerous Goods by Rail.
 Compressed Gas Association, CGA C-6, Standard for Visual Inspection of Steel
Compressed Gas Cylinders, 2007.
 Compressed Gas Association, CGA C-3, Guidelines for Visual Inspection and
Requalification of Low Pressure Aluminum Compressed Gas Cylinders, 2005.
 Compressed Gas Association, ANSI/CGA C-7, Guide to the Preparation of

Precautionary Labeling and Markings of Compressed Gas Containers, 2011.
 National Fire Protection Association, NFPA 10, Standard for Portable Fire
Extinguishers, 2013 Edition.
 National Fire Protection Association, NFPA 25, Standard for the Inspection,
Testing and Maintenance of Water-Based Fire Protection Systems, 2014 Edition.
 National Fire Protection Association, NFPA 58, Liquefied Petroleum Gas Code,
2014 Edition.
2011 Edition.
2008 Edition.
159
Operations & Maintenance Handbook Appendix A
for LP-Gas Storage Facilities References
2004 Edition.
2001 Edition.
1995 Edition.
 National Fire Protection Association, NFPA 70, National Electric Code®, 2014
Edition.
 National Propane Gas Association, Certified Employee Training Program.
 Propane Education & Research Council, Dispensing Propane Safely.
 U.S. Government Publication, Occupational Health and Safety Administration,

OSHA Publication 3072, Sling Safety, 1996 Revision.
 U.S. Government Publication, Title 21, Code of Federal Regulations, “Food and
Drugs”, Chapter I, Part 184.1655.
 U.S. Government Publication, Title 29, Code of Federal Regulations, “Labor”,

Part 1910, General Industry Standards.
 U.S. Government Publication, Title 40, Code of Federal Regulations, “Protection

of Environment.”
 U.S. Government Publication, Title 49, Code of Federal Regulations,

“Transportation”.
160

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OPERATIONS & MAINTENANCE

PERC is governed by a twenty-one member Board of Directors appointed by the National

The recommendations, standards, or recommended practices, as reflected in this document,

By disseminating or publishing this document, PERC is not undertaking to render any

New Text Graphic

Revised Text Other

Action and Reason for Proposed Action

Reference or similar piece

Method of submitting reference material

City, State, Zip:

Section 1: Introduction – Purpose, Scope and Use of Handbook

Background and Purpose

 Operating procedure manuals for all such facilities.

 Retroactivity - The requirements of Chapter 14 were made applicable to new

 Exemption for Small Installations - Written operations or maintenance

As indicated in NFPA 58 §14.1, each LP-Gas retailer is required to meet the

In summary, this handbook is intended to provide owners and operators of these

Section 3, “Emergency Procedures Plan,” gives owners and operators assistance

Section 4, “General Operations & Safety Requirements,” provides guidance,

Section 5, “Plant Operations Procedures,” gives owners, operators and plant

Section 6, “General Maintenance and Inspection Requirements,” offers the

Section 7, “Maintenance and Checklist Procedure,” provides a bulk storage facility

Section 8, “Maintenance of Fire Protection Equipment,” gives guidance for complying

Section 9, “Manufacturers’ Equipment Information,” has been intentionally left blank

Using This Handbook

Accessibility and Review

Section 2: General Facility Information

MANAGEMENT CONTACT INFORMATION

Authorized (Responsible) Facility Representative (name):

LOCAL EMERGENCY RESPONDER CONTACT INFORMATION

Fire Department (name):

Section 3: Emergency Procedures Plan

NO WARRANTY OR MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSES, OR

Legend: Fire Extinguisher =

Empty Cylinder Storage

Section 4: General Operations & Safety Requirements

Section Purpose and Objectives

According to NFPA 58-2014 §14.2 (Operating Requirements), operating procedures that

Site Signage and Markings

Control of Combustible Materials and Ignition Sources

 When delivering to, or connecting to containers or disconnecting from containers.

Open Flames & Other Ignition Sources – Continuous Control

 Prohibiting the installation in pump houses or cylinder filling rooms of:

Open Flames and Other Ignition Sources – Transfer Operations

(a) Engines of LP-Gas cargo tank vehicles constructed and

(b) Engines in buildings as covered by Section 11.13 of

Facility Ignition Sources

Table 4.1 – Ignition Sources

TYPE/NATURE LOCATION CONTROLS OR

Containers – General Requirements

ASME Containers (Pressure Vessels)

ASME Container Data

Table 4.2 – ASME Container Data

CONTAINER #1 CONTAINER #2 CONTAINER #3 CONTAINER #4

Liquid and Vapor Openings

 Locating them in a place that minimizes their exposure to excessive temperatures,

 Cylinders cannot be stored on the roof of any building or structure.

Temporary Stationary Storage

ASME Containers (> 2000 gallon water capacity)

Overfilling Prevention Devices (OPD)

NFPA 58 requires that cylinders with LP-Gas capacities of 4 lb through 40 lb be

 Cylinders used in industrial truck service.

Liquid Level Gauges